Anti-microbial application equipment with controls

ABSTRACT

A control system for monitoring an antimicrobial application system may include a controller having a monitoring program including an operations unit and an interface unit. The operations unit may include a sensor module operatively coupled to a plurality of sensors positioned to detect operation data associated with the application system in real-time. An adjustment module may adjust the operation of the application system. An analysis module may analyze real-time operation data and initiate a specified response when the analysis indicates that a trigger event has occurred. The response may include issuing a notification to a notification device or initiating the adjustment module to perform a control operation to modify the operation of the antimicrobial application system. A remote monitoring center may control multiple and remote application systems. Mobile devices and a control panel may be operable to interface with operations of the antimicrobial application system via the control system.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of Ser. No. 15/057,803, filed Mar. 1,2016, now U.S. Pat. No. 9,491,953 which is a division of U.S. patentapplication Ser. No. 14/846,251, filed Sep. 4, 2015, now U.S. Pat. No.9,289,001 which claims priority to U.S. Provisional Application No.62/048,024, filed Sep. 9, 2014, entitled “Plant Control and MonitoringApparatuses and Systems,” the entire disclosures of which areincorporated herein by reference.

TECHNOLOGY

The present disclosure relates to plant processing equipment forprocessing foodstuffs and control and monitoring systems and interfacesfor the same. More specifically, the present disclosure relates to plantprocessing equipment and monitoring and control systems forantimicrobial treatment of meat products.

BACKGROUND

Industrial plant operations typically involves an array of interactionsbetween complex processes, equipment, regulations, products, logistics,information technology, personnel, and stakeholders. Traditional methodsto address these operations divide the operations into divisions,creating an information gap by complicating the ability of interestedparties to obtain cross relevant information. Due to the informationgap, important interactions and potential synergies are oftenoverlooked. This may occur even within a single operation systemincluding multiple complex processes.

SUMMARY

In one aspect, an antimicrobial application equipment with controlsincludes an antimicrobial application equipment comprising one or morecomponents of the group comprising: a rotary screen filter comprising arotatable, cylindrical body defined by a screen and into whichantimicrobial treatment solution is received for filtration of solidcomponents; a plurality of spray nozzles positioned to directantimicrobial treatment solution onto work pieces as the work pieces areconveyed through a spray cabinet; a dip tank for containingantimicrobial treatment solution and a conveyer for conveying workpieces through the antimicrobial treatment solution contained in the diptank; a suction box configured to fluidically couple to a dip tank andincluding a sensor for sensing a level of antimicrobial treatmentsolution in the dip tank; a capture unit comprising a series ofactivated carbon filters to filter antimicrobial component from anantimicrobial treatment solution; and a capture unit comprising a seriesof activated carbon filters each including a header having a pluralityof arms defining fluid ports for distributing antimicrobial treatmentsolution over the activated carbon. The antimicrobial applicationequipment with controls may further comprise a controller configured toexecute a monitoring program. The controller may include an operationsunit and an interface unit for interfacing users with the controller.The operations unit may comprise a sensor module operatively coupled toa plurality of sensors positioned to detect real-time operation dataassociated with operation of the antimicrobial application equipment; anadjustment module operatively coupled to the antimicrobial applicationunit and configured to adjust the operation of the antimicrobialapplication unit; and an analysis module configured to analyze thereal-time operation data and initiate a specified response when theanalysis indicates that a trigger event has occurred, wherein theresponse comprises at least one of issuing a notification to one or morenotification devices or initiating the adjustment module to perform acontrol operation to modify the operation of the antimicrobialapplication equipment.

In another aspect, the present application is directed to a controlsystem for monitoring an antimicrobial application system. The systemmay comprise a controller comprising a monitoring program including anoperations unit and an interface unit. The operations unit may include asensor module operatively coupled to a plurality of sensors positionedto detect real-time operation data associated with operation of theantimicrobial application system. The operations unit may also includean adjustment module operatively coupled to the antimicrobialapplication system and configured to adjust the operation of theantimicrobial application system. The operations module may furtherinclude an analysis module configured to analyze the real-time operationdata and initiate a specified response when the analysis indicates thata trigger event has occurred. The response may be one of issuing anotification to one or more notification devices or initiating theadjustment module to perform a control operation to modify the operationof the antimicrobial application system.

In another aspect, the present application is directed to a controlsystem for monitoring multiple antimicrobial application systems. Thesystem may include a multi-plant controller comprising a multi-plantmonitoring program. The multi-plant monitoring program may comprise amulti-plant interface unit configured to receive real-time operationdata from a plurality of antimicrobial application systems. Themulti-plant monitoring system may further comprise a multi-plantoperations unit comprising a multi-plant analysis module configured toanalyze the real-time operation data and initiate a specified responsewhen the analysis indicates that a trigger event has occurred. Theresponse may include one of issuing a notification to one or morenotification devices or initiating a plant controller associated withone of the plurality of antimicrobial application systems to modify theoperation of the antimicrobial application system.

In yet another aspect, the present application is directed to a methodof monitoring an antimicrobial application system. The method comprisescollecting operation data from a plurality of sensors; analyzing theoperation data to determine an operational condition; comparing theoperational condition to a set point to identify an administrative statecorresponding to the set point; and applying an administrative decisionrule to the administrative state and initiating a response specified bythe decision rule when the administrative state corresponds to a triggerevent.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an antimicrobial application andrecycling system according to various embodiments;

FIG. 2 is a first side view of the system of FIG. 1;

FIG. 3 is a second side view of the system of FIG. 1;

FIG. 4 is a top view of the system of FIG. 1;

FIG. 5 is a bottom view of the system of FIG. 1;

FIG. 6 is an end view of the system of FIG. 1;

FIG. 7 is another end view of the system of FIG. 1;

FIG. 8 is a perspective view of an alternative arrangement of dip tankand suction box for use in an antimicrobial application and recyclingsystem according to various embodiments;

FIG. 9 is a detail view of the suction box of FIG. 8;

FIG. 10 is a sectional view of the dip tank and suction box of FIG. 8;

FIG. 11 schematically illustrates an overview of a control systemaccording to various embodiments;

FIG. 12 schematically illustrates hardware unite of controller accordingto various, embodiments;

FIG. 13 schematically illustrates features of a control systemconfigured to execute a monitoring program according to variousembodiments;

FIGS. 14A & 14B illustrate a set point table for use with anantimicrobial application system comprising a dip tank according tovarious embodiments;

FIG. 15 illustrates an operation of the analysis module according tovarious embodiments;

FIG. 16 illustrates a control panel according to various embodiments;

FIG. 17 illustrates a graphical user interface according to variousembodiments;

FIG. 18 illustrates a graphical user interface according to variousembodiments;

FIG. 19 schematically illustrates a control system comprising amulti-plant controller configured for real-time data routing and datastorage according to various embodiments;

FIG. 20 schematically illustrates a control system comprising amulti-plant controller configured for real-time data routing and datastorage according to various embodiments;

FIG. 21 illustrates an antimicrobial application unit according tovarious embodiments;

FIG. 22 illustrates a capture unit according to various embodiments; and

FIG. 23 illustrates a downstream filter of a capture unit according tovarious embodiments.

DETAILED DESCRIPTION

In the processing of foodstuffs such as meats, fruits, and vegetables,and particularly in the processing of poultry such as chicken,sanitation of the food product and equipment during processing isextremely important. As herein described, an antimicrobial applicationsystem and associated equipment or methods may be employed to apply anantimicrobial solution, e.g., by spraying or dipping the food productsto be processed, such as raw meat or chicken parts to reduce microbialcontaminants on the meat. As herein described, an antimicrobialapplication system may be configured to recycle antimicrobial solutionsused in connection with food processing. The recycling may includerecycling of antimicrobial solution applied to items associated withfood processing for subsequent application of the recycled antimicrobialsolution to items associated with food processing. The antimicrobialapplication system may include an antimicrobial application unit and arecycle unit. An initial, dilute antimicrobial composition may beprepared and the concentration of the antimicrobial may be controlledautomatically by a control unit. The control unit may include or beoperatively controllable by a processor. The processor may be configuredto access a data storage medium having stored therein instructionsexecutable by the processor to perform one or more operations of theantimicrobial application system. The antimicrobial composition may beprovided to the antimicrobial application unit and applied to workpieces, such as raw poultry carcasses. After application to the workpieces, the antimicrobial composition-containing solution may flow to arecycle tank of the recycle unit. The concentration of the antimicrobialin the antimicrobial solution flowing to the recycle tank may bemonitored manually or by the system. Additional antimicrobial may beautomatically added if the concentration of the antimicrobial in theantimicrobial solution falls below a desired amount. Additionalantimicrobial may also be automatically added at a rate thatapproximates the rate at which the antimicrobial is depleted from thesolution. All or a portion of the antimicrobial solution may beperiodically diverted to a capture tank for selective removal of theantimicrobial composition from the solution. The removed antimicrobialand remaining solution are then disposed of in appropriate manners. Theantimicrobial is preferably a quaternary ammonium compound, analkylpyridinium chloride, or cetylpyridinium chloride (CPC). Variousdifferent antimicrobial solutions are suitable for use, including, forexample, a solution containing cetylpyridinium chloride (CPC). Onesuitable antimicrobial solution is available under the name Cecure fromSafe Foods Corporation.

Referring to FIGS. 1-7, reference numeral 10 refers in general to anarrangement of an antimicrobial application system according to thepresent disclosure. Although exemplary dimensions are given below forvarious components of the system, it should be appreciated that thecomponents can be customized for different processing plants, and aretherefore not intended to be limiting.

In various embodiments, the antimicrobial application system 10 may bepart of a meat processing system employed by a producer or processor ofmeat. The antimicrobial system 10, for example, may be housed within alarger meat processing plant (not shown) with additional processingapparatuses or devices associated with the meat processing system. Thesystem 10 generally comprises an antimicrobial application unit 12configured to apply an antimicrobial solution to work pieces, such asraw meat or poultry carcasses or pieces. In some configurations, theantimicrobial application system 10 may further include or be configuredto fluidically couple to a recycle unit 14 configured to one or more ofreceive, supply, retain, transport, mix, deliver, circulate, treat,measure, and filter the antimicrobial solution. For example, in oneembodiment, the recycle unit 14 is configured to fluidically couple tothe application unit 12 at a first end to receive antimicrobial solutionfrom the application unit 12 and at a second end to deliverantimicrobial solution to the application unit 12. In normal operationof such a configuration, the antimicrobial solution is generallyrecycled through the recycle unit 14 before passing back to theantimicrobial application unit 12. At the end of an allotted time (forexample, a set number of hours, a shift, a day, or longer), processingof the meat products is halted so that the equipment can be cleaned, andthe antimicrobial solution is generally then routed through a capturevalve 16 for capture in a separation unit (not shown). After capture,the antimicrobial solution may be discarded, or processed for furtherre-use, depending on the particular application.

The antimicrobial application unit 12 includes a generally trough-likedip tank 20. The dip tank 20 is connected at either end to conveyors formoving parts through the unit 12. The dip tank 20 includes an inletsection 22, a central section 24, and an outlet section 26. A conveyor(not shown) may run along the floor of the dip tank 20. The conveyer mayinclude a moving rack, cage, hanger, or track configured to convey meatproducts through the dip tank 20. FIGS. 8 and 10 illustrate a conveyer27 according to various embodiments. The conveyer 27 runs along the diptank 20 to convey the meat products through the antimicrobial solution53 within the dip tank 20. The control unit may be configured tomaintain a preferred level 53 a of antimicrobial solution 53. Forclarity, only the portion of the conveyer 27 that extends along theinlet section 22 and through the initial portion of the central section24 is shown. However, the conveyer 27 will typically extend through thelength of the dip tank 20. The conveyer 27 is typically formed of orcoated with a noncorrosive material to limit corrosive effects of theantimicrobial solution. The conveyer 27 may include vertical flights toensure that the meat products are kept continually moving through thedip tank 20. In one embodiment, the conveyer 27 may be a polyethylenebelt, and the flights may be 3″ tall and spaced every 12″ along thebelt, although the particular form of the flights will typically beselected in consideration of the product being processed and can vary.These flights may be formed of solid pieces of polyethylene orpropylene, for example. The outlet section 26 may include a drip regionor drip pan 51 for recycling of excess antimicrobial solution. Forexample, the drip pan 51 may be positioned downstream of theantimicrobial solution 53 held in the dip tank 20 to catch excessantimicrobial solution from meat products or the conveyer that may bereleased along the outlet section 26. In one embodiment, the drip pan 51includes a drain to collect the antimicrobial solution caught in thedrip pan 51. The collected antimicrobial solution may then be recycled,e.g., returned to the bulk of the antimicrobial solution held in thedrip tank 20. The drip pan 51 may also be positioned at an angle towardthe central section 24 to direct the antimicrobial solution caught bythe drip pan 51 toward the bulk of the antimicrobial solution 53 held inthe dip tank 20. The dip tanks illustrated in FIGS. 1-10 are alsoequipped with discharge manifolds 28 a and 28 b provided on each side ofthe central section 24, and extend through apertures 29 in the sides ofthe tank 20.

With reference again to FIGS. 1-7, the recycle unit 14 includes a rotaryscreen filter 30, a rotary screen reservoir 32, a rotary screen shield34, and a rotary screen spray bar 36. The interior of the rotary screenfilter 30 is provided with a screw impeller 38, and each end of therotary screen includes a solid section 40. The rotary screen filter 30may be, for example, a 24″ diameter stainless steel drum having 1/16inch perforated holes therein. It will be appreciated that any suitabletype and size of screen, such as a mesh or different hole sizes orpatterns, may be employed. The screw impeller 38 may take the form of athread that is about 2″ high, and which spirals around the interior ofthe rotary screen filter 30 to form bands that are about 12″ apart.

In various embodiments, the recycle unit 14 includes a rotary screenfilter 30 configured to filter solid components from recycledantimicrobial solution. For example, during application of antimicrobialsolution to work pieces solids may pass into the antimicrobial solution.The solid components may include, for example, large particles, solids,solids associated with liquids, viscous liquids, fat, gelatinousmaterial, debris, or other materials that may be filtered from theeffluent via passage through the size restrictive screen filter 30. Oneor more additional filters (not shown) may be included in theantimicrobial application system 10, particularly for removing largeparticles and solids.

The screen filter may include a body including a filter portion 30positioned between ends 40 of the body. The body may include an annularwall 31 defining a bore that extends along a rotation axis “R” aboutwhich the filter portion 30 is configured to rotate as indicated byarrow 33. In various embodiments, the filter portion 30 may beconstructed from strips of material patterned or cross-laid to form aplurality of holes or a mesh. The body 30 may also be constructed from atube or drum through which perforations are formed to define the holesof the mesh 35 between an inwardly facing surface and an outwardlyfacing surface of the annular wall 31.

The screen filter 30 is preferably coated with or formed of materialsresilient to corrosion, e.g., anti-corrosives, stainless steel,synthetics, polymers, plastics, ceramics, etc. The holes of the mesh 35may be dimensioned to obstruct passage of the solid component having aminimum size or cross-section while allowing passage of the remainingeffluent. In one preferred embodiment, the holes of the mesh 35 aresized to define cross-sections of about 0.0625 inches, however, the mesh35 may include smaller or larger holes as well as fewer or additionalholes, e.g., in consideration of the amount, size, or retentioncharacteristics the solid components, rate or quantity of effluent,rotation rate or area of the filter portion, etc. In at least oneembodiment, the mesh 35 of the filter portion 30 includes holes havingdifferent sized cross-sections.

A primary pump 42 may be configured to pump clean antimicrobial solutionaround the system. The primary pump 42 is connected to a firstdistribution conduit 44, from which extend manifold distributionconduits 46 a and 46 b that are connected to the discharge manifolds 28a and 28 b. The distribution conduit 44 can be, for example, a 2″diameter pipe, and a 2″ to 1″ reducer can be included in the pipe closeto the discharge manifolds 28 a and 28 b. A further distribution conduit47 is connected between the distribution conduit 44 and the rotaryscreen spray bar 36.

The discharge manifolds 28 a and 28 b are located underneath theexpected surface of the antimicrobial liquid in the dip tank 20, butabove the level of a conveyor belt passing through the dip tank 20. Thedischarge manifolds 28 a and 28 b may comprise agitation jets configuredto shoot the antimicrobial solution liquid across the reservoir in thedip tank 20, which helps to flip and roll meat products being conveyedtherethrough, and therefore unstacks the otherwise stacked product. Thisallows for an even contacting of all surfaces of the meat product withthe antimicrobial solution, which is important to non-oxidativeantimicrobial technology such as a CPC-based solution. As CPC has atendency to foam, submerging the discharge manifolds underneath theexpected surface of the liquid in the dip tank 20 helps to reducefoaming.

Underneath the dip tank 20 in the arrangement shown in FIG. 1, a drainconduit 54 is provided. The drain conduit 54 is the primary drain forthe dip tank 20, and will receive antimicrobial solution directly afterit has been applied to the meat products in the dip tank 20. As thissolution will contain organic solids and other particles, the drainconduit 54 may have, for example, an initial diameter of 4″ that maypass through a reducer to a 2.5″ pipe. Drain conduit 54 is connected toa solids pump 56. A recycle conduit 58 leads from the solids pump 56 tothe rotary screen filter 30, and may have, for example, a diameter of2′.

The recycle conduit 58 may include an outlet 60 adjacent to an end 40 ofthe screen filter 30 that is positioned to deliver effluent into thebore of the screen filter 30. In at least one embodiment, the recycleconduit 58 extends partially within the screen filter 30 and the outlet60 may include a downspout directed toward or positioned to deliver theeffluent to a delivery region that extends along an inwardly facingsurface of the annular wall of the screen filter 30. The delivery regionmay include a band forming one end 40 defining a perimeter of the bore.The band may be formed of the same or a different material as the filterportion 30. The band 40 may have a solid or continuous inwardly facingsurface 41 with respect to the bore. The inwardly facing surface 41 maybe smooth to discourage accumulation of solid component or fromotherwise obstructing flow of effluent from the delivery region towardthe filter portion 35. For example, the inwardly facing surface 41 mayinclude a polished metallic surface.

In at least one embodiment, the inwardly facing surface 41 of the band40 may be textured to include grooves or projections. The grooves may beoriented to provide fluid paths for effluent directed toward the filterportion or to breakup solid components. In one embodiment, the inwardlyfacing surface 41 may be treated or coated with a non-stick material todiscourage accumulation of solid component. In some embodiments, theabsence of holes defined in the inwardly facing surface 41 of the band40 may allow effluent to be delivered into the bore onto the inwardlyfacing surface 41 while avoiding forcing accompanying solid componentonto the filter portion 35 where it may become lodged. The screen filter30 may include bands 40 positioned at both ends of the body. However, inat least one embodiment, the screen filter 30 includes only one band 40.The screw impeller 38 on the interior of the rotary screen filter 30helps to move solid particles to the other end 40 of the rotary screenfilter, where the particles can fall out of the rotary screen filterinto a collection container (not shown) for provision to a further meatprocessing step, for disposal, or recycling, depending on theapplication.

In a further embodiment, a lip or ridge may be disposed at an end of thebody of the screen filter 30 adjacent to the delivery region to preventeffluent from exiting the bore without passing onto the filter portion35. In at least one embodiment, however, the inwardly facing surface ofthe band 40 may be positioned at a raised angle with respect to thehorizontal to urge the effluent directed onto the inwardly facingsurface 41 of the band 40 toward the filter portion 35 of the screenfilter 30. The raised angle may position the inwardly facing surface 41to oppose the direction of effluent flow with respect to its releasefrom the outlet 60 to redirect the effluent toward the filter portion 35or may complement the general direction of flow of the effluent towardthe filter portion 35. In this or other embodiments, the body 35 of thescreen filter 30 may be positioned at an angle with respect to thehorizontal such that one end thereof is raised relative to the opposingend. The angle of the body 35 may further angle the inwardly facingsurface extending along the filter portion 35. Accordingly, the outlet60 of the recycle conduit 58 may be positioned to release effluent ontothe inwardly facing surface 41 at a high end of the band 40. In these orother embodiments, the outlet 60 may be angled to direct the effluentinto the bore or onto the inwardly facing surface 41 of the band 40 at aperpendicular, parallel, or other angle in-between.

As introduced above, the filter portion 35 of the screen filter 30 maybe configured to rotate about a rotation axis R as generally identifiedby arrow 33. In at least one embodiment, the body 35 of the screenfilter 30, which may include the band 40, may also be configured torotate with the filter portion 35. The rotation may be driven by anysuitable mechanism configurable to rotate the filter portion 35 of thescreen filter 30, such as gears, pulleys, motors, etc.

In at least one embodiment, the screen filter 30 includes a screwimpeller 38 configured to urge effluent through the bore. For example,the screw 38 may be configured to urge liquid portions of the effluentalong the inwardly facing surface of the annular wall of the screenfilter 30, such as the inwardly facing surface 41 of the band 40, towardthe filter portion 35. The screw 38 may also be configured to urge solidcomponents along the annular wall through the bore of the screen filter30 toward a solids trap (not shown). The solids trap may, for example,be located at an end of the body 35 where solid components may bereleased for disposal. The screw 38 may include a thread protruding fromthe annular wall toward the rotation axis R. The thread may wrap aroundthe annular wall within the bore between the ends 40 of the body 35 toform a helix therein. The thread may be directionally oriented tocomplement the rotation of the filter portion 35 to direct separatedsolid components toward an end 40 of the bore where the solid componentsmay then be passed for disposal. For example, the thread may wrap aroundthe inwardly facing surface in a clockwise or counterclockwise directionwith respect to an end 40 of the body 35 to directionally urge solidcomponents toward or away from the end 40 of the body 35 as induced bythe direction of rotation and location of the delivery region.

In various embodiments, the screen filter 30 may include or beconfigured for implementation with a cleaning unit 36. In one form, thecleaning unit 36 may be a spray bar, and may be used to clean one ormore portions of the screen filter 30, e.g., dislodge solid componentsfrom the annular wall or filter portion 35, provide additionallubrication to encourage passage or solid components through the bore,discourage accumulation of solid components on annular wall or filterportion 35, etc. The cleaning unit 36 may be equipped with a scraperconfigured to implement cleaning operations of the cleaning unit 36. Thescraper may be positioned within or outside the bore. In variousembodiments, the scraper may employ various mechanisms to scrape thescreen filter 30. For example, the scraper may include one or moreextensions such as bristles or rigid or elastomeric flaps, for example,configured to contact the inwardly or outwardly facing surfaces of theannular wall or body 35 of the filter screen 30.

In the illustrated embodiment, the spray bar 36 can have one or morefluid ports 37 configured to direct a fluid onto the annular wall toclean the screen filter 30, e.g., to dislodge solid components from thefilter portion 35 or encourage solid components to move along a lowerportion of the bore of the filter screen 30 by the action of the screw38. In at least one embodiment, the spray bar 36 is positioned withinthe bore to direct fluid onto the inwardly facing surface of the annularwall, e.g., along the filter portion 35 or bands 40. In someembodiments, multiple spray bars 36 or fluid ports 37 may also bepositioned around the body 35 or both within the bore and along theoutwardly facing surface. The fluid ports 37 may include nozzlesconfigured to directionally enhance or modulate distribution of thecleaning fluid. In certain embodiments, the fluid ports 37 may bestatically positioned. Regulation of volume or pressure of cleaningfluid directed from the fluid portions may be modulated using pumps,restriction or obstructive elements, valves, etc. For example, in oneembodiment, an orifice plate may be disposed in the spray bar 36. Theorifice plate may be positioned to modulate flow for a single ormultiple fluid ports 37, for example. In at least one embodiment, thefluid ports 37 may be movable via a central control unit, e.g., in apredetermined or programmed pattern or selectively, which may includesensors configured to sense locations in need of the cleaning action ofthe fluid and that which send such data to the central control unit forautomated directing. In this or another embodiment, the fluid ports 37may be manually directed via remote controls provided by a user remotecontrol system incorporated with the central control unit.

A distribution conduit 48 is connected to first distribution conduit 44,and provides clean antimicrobial solution to the rotary screen spray bar36. The distribution conduit 48 may be, for example, a 1″ diameter pipe.Antimicrobial solution is filtered through the rotary screen filter 30,and falls on the flow of solid particles being impelled through therotary filter screen 30, and then out through the bottom of the filterinto the rotary screen reservoir 32.

Two outlets are provided in the rotary screen reservoir 32, and areconnected to respective conduits. A recycle conduit 50 is connected toan outlet in the bottom of the rotary screen reservoir 32, and isconnected in with the first distribution conduit 44 and primary pump 42.An overflow pipe 52 is connected to an outlet at an upper edge of therotary screen reservoir 32. Overflow pipe 52 is located generally higherthan the expected liquid level in the rotary screen reservoir, and maybe, for example, a 3″ diameter pipe. The overflow pipe 52 can bedirected to the top of dip tank 20, and does not need to include a pumpas the rotary screen reservoir 32 is positioned above the level of thedip tank 20.

In a normal work shift, the antimicrobial fluid is constantly filteredand recycled in real-time, in a closed loop system, which has a highlevel of recycling efficiency that retains all of the antimicrobialsolution therein. Three capture valves 60, 62, and 64 are provided inthe conduit systems so that at the end of a shift, the antimicrobialsolution flow can be stopped and can be drained to a capture pipe 66 forcapture and further processing. It will be noted that fluid flowing intothe capture pipe 66 has been filtered by the rotary screen filter 30during both the recycle process, and the drain process. This allows thecapture line to include a finer grade of filter, such as a carbon filterwithout having to provide an additional large-scale filter.

Referring now to FIGS. 8-10, an alternative form of drainage from thedip tank 20 is shown. Instead of a drain on the bottom of the dip tank,a suction box 70 is provided to the side of the dip tank 20. The suctionbox 70 includes a box attached adjacent to an aperture 72 that is cut inthe side wall of the dip tank 20. The suction box 70 is separated fromthe dip tank 20 by a plurality of round bars 74 that act as a screen toprevent the ingress of larger pieces of meat product into the suctionbox. The bars 74 do not extend all the way to the top of the aperture72, so that fluid can flow in easily to the suction box, which enablessensors in the box to detect that a sufficient level of liquid ispresent in the dip tank. For example, a gap of 3-4″ may be left betweenthe top of the bars 74 and the top of the aperture 72. This prevents thebars 74 from becoming clogged with smaller meat particulates that mayinterfere with the operation of sensors 76 in the box, for example,pressure transducers from which the fluid level in the dip tank 20 canbe calculated. By placing the sensors in the suction box 70, they can bemore easily cleaned or replaced when needed, and by allowing for freeflow of fluid into the box 70, the sensors can measure the fluid levelin the tank 20 accurately. If needed, the suction box 70 can be brieflyseparated from the dip tank 20 using a solid plate, so that the sensorsmay be cleaned, while the system is still running, and without stoppingthe conveyor 27 and bringing the processing system offline in the middleof a shift. Larger meat parts do not clog the suction box bars 74 evenwith an aperture above the bars, as the larger parts are heavier andremain on the conveyor 27, and are thus prevented from entering thesuction box (and hence the recycling conduits) by the bars 74 acting asa filter. One or more drain holes 68 are provided in the base or sidesof the suction box 60, to suction away the antimicrobial solution forfiltering.

As introduced above, the dip tank 70 illustrated in FIGS. 8 and 10 isconfigured with an outlet section 26 comprising a drip pan 51. The drippan 51 may include a downstream length of the outlet section 26 withrespect to the central section 24. The drip pan 51 may be integral withthe length of the outlet section 26 or may be provided by one or morelengths of modular drip pan extensions 55 that may be coupled to theoutlet section 26 to extend the length of the drip pan 51 along theoutlet section 26. The drip pan 51 is configured to catch excessantimicrobial solution that associates with the meat products orconveyer after passing through the central section 24. In thisembodiment, the drip pan 51 is positioned at an inclined angle away fromthe central section 24 to direct the excess antimicrobial solutioncaught by the drip pan 51 back toward the antimicrobial solution 53within the central section 24 of the dip tank 20. Sensors configured todetect meat products conveyed along the conveyer may be placed along theoutlet section 26. For example, in one embodiment, photo eye sensors arepositioned adjacent to the conveyer 27 to detect meat products conveyedalong the drip pan 51.

The dip tank 20 also includes a stop drip pan 57 downstream of the drippan 51. The stop drip pan 57 is configured to isolate a rinse solution,which may be applied to the meat products during a rinse application 59,from being recycled with the antimicrobial solution caught by the drippan 51 or otherwise entering the antimicrobial solution 53. The rinseapplication 59 may include one or more spray bars having spray nozzles,e.g., vee-jet nozzles for directing the rinse solution 61 onto the meatproducts after the meat products have been removed from the dip tank 20.The nozzles may be positioned to direct rinse solution 61 to completelycover the width of the conveyer and hence the meat products conveyed, onthe conveyer 27. The stop drip pan 57 may include a barrier such as aprojection or gap positioned between the drip pan 51 and rinseapplication 59 configured to maintain separation of the rinse solution61 and the drip pan 51. When a gap is used, rinse solution 61 may bedirected toward the stop drip pan 51 which may include a drain forcollecting rinse solution 61 following application. In the illustratedembodiment, the stop drip pan 51 includes a length that is horizontal ordeclined with respect to the drip pan 51 or separated from the of drippan 51, e.g., includes a gap, to maintain separation of the rinsesolution 61 from the antimicrobial solution 53. Accordingly, the stopdrip pan 57 may be configured to stop rinse solution 61 from dilutingthe antimicrobial solution 53.

Administration of a plant operations system in commercial manufacturingor production processes may include a control system configured tointegrate various monitoring and control operations into a centralizedresource comprising automation, analysis, operational control andmonitoring functionalities. For example, the control system may beconfigured to perform administrative functions with respect to theoperation of one or more plant operations systems and associatedequipment. The control system may also be configured to integrate one ormore of the collection, analysis, storage, access, communication, anddistribution of operation data, which may be distributed or madeavailable to specified personnel or devices as defined in the system.

FIG. 11 provides an overview of a control system 100 for administeringan operations system 102 according to various embodiments. The controlsystem 100 comprises a flexible platform from which various tasks orfunctions related to the operations of the plant operations system 102,e.g., controlling or monitoring the anti-microbial equipment of theplant operations system 102, may be configured, defined, controlled,performed, or monitored. The control system 100 may include a controller103 configured to perform various monitoring and control tasks withrespect to the plant operations system 102. In one embodiment, the plantoperations system 102 may include a foodstuff antimicrobial applicationsystem, which is some applications may include features similar to thosedescribed above with respect to the antimicrobial application system 10.In other embodiments, the plant operations system 102 may include anantimicrobial spray applications similar to those described in U.S. Pat.No. 6,742,720, issued Jun. 1, 2004, titled SPRAY APPLICATION SYSTEM, thecontents of which are herein incorporated by reference in its entirety.The plant operations system 102 may also include antimicrobial recyclingfeatures similar to those described above or antimicrobial capturefeatures, e.g., as described in U.S. patent application Ser. No.14/510,385, filed Oct. 16, 2014, and titled: ANTIMICROBIAL APPLICATIONSYSTEM WITH RECYCLE AND CAPTURE, the contents of which are hereinincorporated by reference in its entirety. However, it will beappreciated that the control system 100 may be implemented to providevarious control or monitor operations with respect to other operationssystems 102 used in various commercial, processing, manufacturing, orindustrial applications.

In various embodiments, the controller 103 is configured to operativelyassociate with one or more sensors (not shown) positioned to sense,detect, or measure conditions of the plant operations system 102 inreal-time. The controller 103 may be configured to route or makeavailable operation data to one or more operations database 104 orinterfaces 105. The operations database 104, for example, may beaccessed by the controller 103 to retrieve, store, or archive controlsystem data, which may include raw, processed, or analyzed operationdata, events, as well as parameter definitions, including rules,statistics, tables, algorithms, or other data used to process or analyzedata including generating or identifying operational conditions, asdescribed in more detail below. For example, the operations database 104may include files executable by the controller 103 to perform one ormore aspects of the monitoring program 120. The controller 103 may beunder the control of the monitoring program 120 configured to interfacethe functionalities of the controller 103 with users and access devices142. The monitoring program 120 may define various administrativeparameters, e.g., definitions or settings, of the control system 100such as operational and administrative decision rules including setpoints, operational condition identification, and analysis parameters,any of which may include customizable definitions to fit a desiredapplication. For example, the controller 103 may be operativelyassociated with one or more processes of the plant operations system 102to monitor, collect, analyze, process, and/or communicate dataindicative of operational conditions, events, or states as defined bythe monitoring program 120.

The controller 103 may also be configured to process the operation data.For example, the controller 103 may analyze the operation data todetermine operational conditions, format the operation data into adesired format or generate reports, e.g., enter select data or analyzeddata into predefined forms or according to requests received from usersvia access devices 142. In one embodiment, the controller 103 may beprogrammed to activate, deactivate, or modulate system pumps or valves,to receive, transmit, or process data signals in communication with oneor more components of the plant operations system 102, or to process oranalyze data communicated from one or more of the sensors operativelyassociated with various operation units of the plant operations system102. For example, the sensors may be configured to detect contaminantsor other aspects of antimicrobial fluid composition used for treatmentof work pieces. The controller 103 may be operatively associated withone or more data transmission devices which may receive or store datareceived from or processed by the controller 103. In certainembodiments, the controller 103 may communicate signals to one or moreinterfaces, e.g., programs, control system or external devices, accessdevices 142 or applications, or indicators which reflect a condition,event, state, activity, or function of the plant operations system 102.For example, one such indicator may include a notification, which mayinclude activation of a warning light, an audible alert, or a messagesent to and displayed on a graphical display associated with a local orremote notification device, plant monitor, or access device.

Analysis of operation data may include the controller 103 utilizingadministrative parameters comprising analysis tools to determine,calculate, or classify an operational condition, event, or state andthen performing or initiating a predefined response or action inaccordance with administrative decision rules specified in themonitoring program 120. For example, the controller 103 may compare rawor processed operation data or an operational condition determined usingsuch data to predefined set points. Set points may include measurablestandards identified or specified by a user or otherwise defined in themonitoring program 120. Set points may include, for example, depth orvolume of antimicrobial treatment solution within a dip tank of theapplication unit or recycle unit, discharge manifold or agitation jetpressure applied to jets within the dip tank, conveyer rate, nozzle orline pressure, pump or valve states, antimicrobial concentration,recycle rate, or capture parameters such as rate of capture, effluentcomposition or flow rate, or expected filter efficiency or remaininglife.

When a set point comparison identifies an occurrence of a trigger event,the controller 103 may respond in a predefined way. For example, thecontroller 103 may transmit to one or more interfaces 105 anotification, alert, or alarm. Additionally or alternatively thecontroller 103 may perform or initiate a control operation specified bya decision rule, e.g., modulate an operation of the plant operationssystem 102 to address a trigger event. In various embodiments, setpoints or the predefined response to a trigger event may be staticallyor dynamically defined and, thus, may be beneficially configurable toadapt to different operational conditions or circumstances within anygiven application. In one embodiment, an authorized user may define thestatically or dynamically defined response to one or more triggerevents.

FIG. 12 illustrates various hardware units of a controller 103 accordingto various embodiments. In general, the controller 103 may include oneor more processors, servers, databases, networks or network devices, andperipherals configured to obtain and transmit data and initiate controloperations configured to perform in whole or in part the operations ofthe monitoring program 120. As shown, the controller 103 comprises aprocessing unit 106, e.g., one or more electronic data processors orcentral processing units having logic control functionalities. Thecontroller 103 further comprises a memory unit 107 comprising one ormore electronic data storage mediums such as recording media, read-only,volatile, non-volatile, semiconductor based, or other data storagemediums known in the art. The memory unit 107, for example, includes oneor more data storage mediums having stored thereon one or more programsor applications comprising software, firmware, or other instructionsstored in one or more files executable by the processing unit 106 toperform the various operations and functions of the controller 103. Theinstructions may include the plant monitoring program 120 or operatingsystem configured to monitor or control plant operations and interfaceusers or access devices 142, which may include interaction withadditional applications or services.

The controller 103 may also include a communication unit 108 configuredto transmit and receive data. The communication unit 108 may include oneor more data ports, communication ports, transmitters, receivers,transceivers, network cards, modems, gateways, routers, switches,firewalls, local, virtual, wide area, cloud/internet area, orinternet-based distributed networks, Ethernet, wireless or wired digitalcommunication devices, telecommunication devices, monitors, speakers,lights, buttons, knobs, or peripherals. The controller 103 may alsoinclude or be operationally associated with control and monitoringcomponents such as sensors, actuators, valves, pumps, power switches,etc. for controlling or monitoring operational conditions of the plantoperations system 102.

The controller 103 may be configured to initiate or otherwise providecontrol instructions to the plant operations system 102 to modulateplant operations in response to a determination, e.g., to maintain oraddress deviations in set points. The controller 103 may further beconfigured to generate event logs, updates, and notifications such asalerts or alarms according to administrative parameters or rules definedby the monitoring program 120 or, in some embodiments, as requested byan authorized user or device. The controller 103 may be configured totransmit operation data to specified access devices 142, users, or theoperations database continuously, periodically, in batches, or asotherwise specified in the monitoring program 120, The controller 103may also be configured to transmit administrative responses in responseto trigger events as defined by the monitoring programs 120administrative decision rules.

FIG. 13 illustrates one embodiment of the control system 100 accordingto various embodiments. The control system 100 may comprise one or morenetworks including networked devices, e.g., nodes or endpoints,configured to communicate via wired or wireless connections. Networksmay comprise local, virtual, wide area, cloud/internet area, orinternet-based aspects. The networks may include one or more distributedcommunication networks that may include virtual hardware, distributeddatabases, parallel or distributed computing schemes, service orientedapplication architectures, public, private, or hybrid clouds, openarchitectures or architectures utilizing web API, web applications, ormashups, and may employ client-server or peer-to-peer models.

The plant operations system 102 includes machinery, apparatuses,configurations, and processes by which a plant performs plantoperations. For illustrative purposes, the plant operations system 102depicted in FIG. 13 includes an antimicrobial application system 110,however, the control system 100 may be used to monitor and control otheror different operations systems 102. That is, while the control system100 is described herein in the context of antimicrobial applicationsystem 110 for clarity and brevity, it is to be understood that unlessspecified otherwise the control system 100 may find application inbroader contexts such as in manufacturing or other plant processes. Theantimicrobial application system 110 may be configured to prepare,circulate, apply, or dispose of antimicrobial treatment solution andtransport work pieces for application of the antimicrobial treatmentsolution. The antimicrobial application system 110 may include variousoperation units comprising pumps, valves, filters, nozzles, piping,reservoirs, conveying devices, etc., such as those described herein withrespect to FIGS. 1-10 and 21-23.

As shown, the antimicrobial application system 110 comprises anapplication unit 112, a recycling unit 114, and a separation unit 116.The application unit 112 may be configured to apply antimicrobial ontosurfaces of work pieces, e.g., raw meat or other food products. Theapplication unit 112 may be similar to the application unit 12 describedabove and in U.S. patent application Ser. No. 14/510,439, filed Oct. 16,2014, and titled: CLOSED LOOP RECYCLING SYSTEM AND DIP TANK FORANTIMICROBIAL COMPOUNDS, the contents of which are herein incorporatedby reference in its entirety. For example, the application unit 112 mayinclude a dip tank containing antimicrobial treatment solution andthrough which work pieces are transported.

In another embodiment, the application unit 112 may be configured toapply antimicrobial onto surfaces of work pieces using other oradditional manners of application. For example, the application unit 112may include a cabinet or chamber into which fluid ports or spray nozzlesinject or pour a supply antimicrobial treatment solution onto workpieces conveyed thorough the cabinet or chamber. An example of which, isillustrated in FIG. 21. The application unit 112 may comprise a anapplication unit 123 comprising a cabinet 125. A conveyer 161 extendsthrough the cabinet 125 and is configured to transport work pieces 163through the cabinet 125. A spray bar comprising a plurality of spraynozzles 165 positioned to direct antimicrobial treatment solution 53onto the work pieces is positioned adjacent to the cabinet 125. Theantimicrobial treatment solution 53 is collected at the cabinet forrecycling by the recycle unit 114. A pump may thereafter transport therecycled solution 53 back through the spray bar for additionaltreatments. An orifice plate 167 may be positioned between the pump andthe spray nozzles 165 to maintain a consistent rate of flow from thenozzles 165. At the end of a treatment cycle, for example, antimicrobialeffluent 235 may be transported to a capture unit 116 for capture ofantimicrobial component and disposal of the filtrate 249. Furtherexamples of application units 112 are described in U.S. Pat. No.6,742,720, issued Jun. 1, 2004, titled SPRAY APPLICATION SYSTEM and U.S.patent application Ser. No. 14/471,846, filed Aug. 28, 2014, and titledAPPLICATION SYSTEM WITH RECYCLE AND RELATED USE OF ANTIMICROBIALQUATERNARY AMMONIUM COMPOUND, the contents of both are hereinincorporated by reference in their entirety. In another embodiment, theapplication unit 112 may comprise a mobile applicator configured totransit over work pieces and apply antimicrobial to the surfaces of workpieces. Accordingly, the application unit 112 may include conveyersconfigured to convey work pieces or applicators through the application,unit 112 for application of the antimicrobial treatment solution ontothe work pieces. The conveyers may include moving surfaces such astracks, belts, racks, cages, baskets, or hooks, for example, configuredto engage and convey work pieces through the application unit 112. Theapplication unit 112 may further include piping systems configured totransport various quantities of the antimicrobial treatment solution orits components through the application unit 112 and may include pumpsfor transporting the solution or components and valves configured tomodify the transport, e.g., to control routing or to regulate pressureswithin the piping systems.

The recycle unit 114 may be similar to the recycle unit 14 describedabove and thus may be configured to recycle antimicrobial treatmentsolution thorough the application unit 112. For example, the recycleunit 114 may include piping, filters, pumps, valves, fluid ports, or thelike configured to transport the solution to, from, or through theapplication unit 112. An example of another recycle unit 114controllable by the control system 100 is described in U.S. patentapplication Ser. No. 14/510,385, filed Oct. 16, 2014, and titledANTIMICROBIAL APPLICATION SYSTEM WITH RECYCLE AND CAPTURE, the contentsof which are herein incorporated by reference in its entirety.

The capture unit 116 may be configured to capture an antimicrobialcomponent from the antimicrobial treatment solution. The operations ofthe separation unit 116 may generally include filtering of antimicrobialtreatment solution to separate the antimicrobial component from thesolution prior to disposal, for example, at the end of a treatment cyclesuch as at the end of a shift or a day or other chosen period of time,to purged all or a portion of the antimicrobial treatment solution fromthe treatment system 110. The purging may include initiation of acapture sequence or transition to a capture mode that coordinates pumpand valve operations to thereby direct the antimicrobial treatmentsolution to the separation unit 116.

The controller 103 may be programmed to sequentially or simultaneouslyactivate or deactivate one or more valves or otherwise operate a valveor valve apparatus in response to a purge signal. In one configuration,during a purge of the antimicrobial application system 110, thecontroller 103 may coordinate opening or closing of one or more systemvalves and the powering on or off of one or more system pumps to emptythe antimicrobial application system 110 of antimicrobial treatmentsolution for processing and disposal of the effluent. The purge signalmay be transmitted by a user via an access device 142 or by thecontroller 103 as a predefined administrative response to a triggerevent. Such trigger events may be associated with a condition of theantimicrobial treatment solution, an operational condition of one ormore units of the system 110, which may be determined from analysis ofoperation data and determination of operational conditions withreference to one or more set points, the occurrence of a predeterminedevent (e.g., number of work pieces processed or fixed period of time),or a variety of other operational conditions. In addition to purging orturning over the antimicrobial application system 110, the controller103 may be configured to coordinate transport of dilute antimicrobialtreatment solution to the separation unit 116 for processing anddisposal as part of other system operations, which may include aresponse to a trigger event, for example, to dispose of diluted samplesof antimicrobial treatment solution used for performing antimicrobialcomponent concentration measurements, to adjust the volume ofantimicrobial treatment solution circulating through the applicationunit 112 or recycle unit 114, to partially turnover the system fluids toaddress a low level contamination, or as otherwise desired.

FIG. 23 illustrates a capture unit according to various embodiments, thecapture unit 116 comprises an upstream filter 225 configured to filtersolid component 231, e.g., debris for treated work pieces, of desiredsize from the effluent 223 and a downstream filter 227 configured tocapture antimicrobial component from the effluent 223. The upstreamfilter 225 may include a screen filter 225 a. The screen filter 225 amay include a screw 285 configured to urge effluent 223 through the bore261. For example, the screw 285 may be configured to urge liquidportions of the effluent 223 along the inwardly facing surface 265 ofthe annular wall 259, such as the inwardly facing surface 277 of theband 275, toward a filter portion 255 comprising a mesh 263. The screw285 may also be configured to urge solid components 231 along theannular wall 259 through the bore 261 toward a solids trap 284. Thesolids trap 284 may, for example, be located at an end 257 of the body253 where solid components 231 may be released for disposal. The screw285 may include a thread 287 protruding from the annular wall 259 towardthe rotation axis R. The thread 287 may wrap around the annular wall 259within the bore 261 between the ends 257 of the body 253 to form a helixtherein. The thread 287 may be directionally oriented to complement therotation 273 of the filter portion 255 to direct separated solidcomponents 231 toward an end 257 of the bore 261 where the solidcomponents 231 may then be passed for disposal. For example, the thread287 may wrap around the inwardly facing surface 265 in a clockwise orcounterclockwise direction with respect to an end 257 of the body 253 todirectionally urge solid components 231 toward or away from the end 257of the body 253 as induced by the direction of rotation and location ofthe delivery region 265.

In various embodiments, the screen filter 225 a may include or beconfigured for implementation with a cleaning unit 289. In one form, thecleaning unit 289 may be used to clean one or more portions of thescreen filter 225 a, e.g., dislodge solid components 231 from theannular wall 259 or filter portion 255, provide additional lubricationto encourage passage or solid components 231 through the bore 261, ordiscourage accumulation of solid components 231 on annular wall 259 orfilter portion 255.

The cleaning unit 289 may be equipped with a scraper 291 configured toimplement cleaning operations of the cleaning unit 289. The scraper 291may be positioned within or outside the bore 261. In variousembodiments, the scraper 291 may employ various mechanisms to scrape thescreen filter 225 a. For example, the scraper 291 may include one ormore extensions such as bristles or rigid or elastomeric flaps, forexample, configured to contact the inwardly or outwardly facing surfaces265, 267 of the annular wall 259 or body 253. In the illustratedembodiment, the scraper 291 includes a spray bar 293 having one or morefluid ports 295 configured to direct a fluid onto the annular wall 259to clean the screen filter 225 a, e.g., to dislodge solid componentsfrom the filter portion 255 or encourage solid components 231 to movealong a lower portion of bore 261 by the action of the screw 285. In atleast one embodiment, the spray bar 293 is positioned within the bore261 to direct fluid onto the inwardly facing surface 265 of the annularwall 259, e.g., along the filter portion 255 or bands 275. In someembodiments, multiple spray bars 293 or fluid ports 295 may also bepositioned around the body 253 or both within the bore 261 and along theoutwardly facing surface 267.

The fluid ports 295 may include nozzles 297 configured to directionallyenhance or modulate distribution of the cleaning fluid. In certainembodiments, the fluid ports 295 may be statically positioned.Regulation of volume or pressure of cleaning fluid directed from thefluid portions may be modulated using pumps, restriction or obstructiveelements, valves, etc. For example, in one embodiment, an orifice platemay be disposed in the spray bar 293. The orifice plate may bepositioned to modulate flow for a single or multiple fluid ports 258,for example.

In at least one embodiment, the fluid ports 295 may be movable via thecontroller 103, e.g., in a predetermined or programmed pattern accordingto the monitoring program 140 or selectively, as directed by a userinterfacing with the controller 140 using an access device 142 (whichmay be a mobile or remote access device or the control panel 138) whichmay include sensors operatively coupled to the sensor module 124configured to sense locations in need of the cleaning action of thefluid and that which send such data to the controller 103 for automatedor manual directing. In this or another embodiment, the fluid ports 295may be manually directed via remote controls provided by a user remotecontrol system incorporated with the controller 103, e.g., the interfaceunit 122 may be configured to provide a remote interface accessible byinterfacing an access device 142 or control panel 138 with themonitoring program 140 and transmitting control operations, settings, orother instructions therefrom.

The capture unit 116 may further include a capture tank 216. The capturetank 216 may be positioned along the downstream capture line 237 betweenthe upstream and downstream filters 225, 227 and may include a reservoir218 for retaining effluent 223. The capture tank 216 may include aninlet 211 to receive the upstream effluent filtrate 235 from theupstream filter 225. The upstream filter 225 may direct or the inlet 211of the capture tank 216 may be positioned to receive the upstreameffluent filtrate 235 directly from the upstream filter 225. Forexample, the inlet 211 or reservoir 218 may be positioned adjacent toand downstream of the filter portion 255. In some embodiments,additional capture tanks 216 may be included, e.g., the screen filter225 a may include a capture tank 216 positioned to catch upstreameffluent filtrate 235 passed through the filter portion 255 which maysubsequently be passed to the downstream capture line 237, which mayinclude an additional capture tank 216. In at least one embodiment, thecapture tank 216 is disposed between a first portion of the downstreamcapture line 237 a and a second portion of the downstream capture line237 b.

The capture tank 216 may also include an outlet 213 through whicheffluent 223 may be passed downstream to the downstream filter 227. Theoutlet 213 may be coupled to the downstream capture line 237 and includea drain or valve configured to open the outlet to allow the effluent 223to pass from the capture tank 216 into the downstream capture line 237toward the downstream filter 227. For example, the valve may beconfigured for manual actuation or automated actuation based on a time,volume of upstream effluent filtrate 235 in the reservoir 218, orcapacity of the downstream filter 227. Automated actuation may be inresponse to a signal provided by the controller 103 according to themonitoring program 140, e.g., in response to a trigger event or asinstructed by a user interfacing with the controller 103 via themonitoring program 140 with the control panel 138 or authorized accessdevice 142, which may be a mobile or remote access device 142 comprisinga remote interface, or the valve may be mechanically configured toactuate based on a condition of the system, e.g., an upstream ordownstream pressure.

Transport of the effluent 223 from the outlet 213 toward the downstreamfilter 227 may be promoted, for example, by gravity or a pump disposedin or operatively coupled to the downstream capture line 237. In variousembodiments, the capture tank 216 may include a siphon. For example, thesiphon may be fluidically coupled to the downstream capture line 237.The siphon may be configured to allow the upstream effluent filtrate 235to collect in the capture tank 216, until it reaches a desired level,wherein the siphon thereafter empties or relieves a predetermined volumeof the upstream effluent filtrate 235 from the capture tank 216 andpasses the effluent 223 through the downstream capture line 237 towardthe downstream filter 227. By incorporation of the siphon or othermechanism configured to avoid continuous passage or trickle of effluent223, e.g., wherein the monitoring program 140 is configured to initiatethe controller 103 to actuate the valves at various time intervals orupon receiving an actuation signal from the monitoring program 140,e.g., in response to a trigger event or as instructed by userinterfacing with the controller 103 with the control panel 138 or remoteaccess device 142, the capture unit 116 may reduce or eliminateincidences of channeling with respect to the downstream filter 227. Inat least one embodiment, however, the capture unit 116 does notincorporate a siphon or other mechanism configured to avoid continuouspassage of effluent 223. In one such embodiment, the capture unit 116does not include a capture tank 216, rather the downstream capture line237 is positioned to collect the upstream effluent filtrate 235 from thescreen filter 225 a and pass the upstream effluent filtrate 235 directlyto the downstream filter 227 for continuous processing of the effluent223 transported to the capture unit 116. As such, the capture unit 116may be configured for continuous capture and disposal of effluent 223.

The downstream filter 227 may include an antimicrobial separation unit241. The antimicrobial separation unit 241 may include one or morefilter units 227 a, 227 b, such as disposable carbon filters forselective removal of the antimicrobial component from the effluent 223,wherein the antimicrobial is preferably a quaternary ammonium compound,an alkylpyridinium chloride, or cetylpyridinium chloride. As describedabove, the filter units 227 a, 227 b may be configured to exploit one ormore characteristics of the effluent 223 or its components to achievethe desired separation of the antimicrobial component 245 from theeffluent 223 using any suitable filter strategy and design. In theillustrated embodiment, the filter units 227 a, 227 b of the separationunit 241 of the downstream filter 227 include at least two filter unitsthat are aligned in series. Each filter unit 227 a, 227 b includes acontainer 242 having an outer surface 270 for housing a filter material243, such as activated carbon, through which the upstream effluentfiltrate 235 may be passed for separation of the antimicrobial microbialcomponent 245, e.g., via reaction or adsorption onto the filter material243. While two filters units 227 a, 227 b are shown, additional filtersmay be used. For example, in one embodiment, the downstream filter 227includes a separation unit 241 having between two and four filter units227 a, 227 b aligned in series, wherein each filter unit 227 a, 227 bincludes a container for retaining a supply of filter material 243including activated carbon.

The downstream filter 227 may include an outlet configured to be coupledto a disposal line 247 to allow downstream effluent filtrate 249 to exitthe separation unit 241. In various embodiments, the separation unit 241is configured to separate a suitable quantity of antimicrobial component245 from the upstream effluent filtrate 235 such that the resultantdownstream effluent filtrate 249 is characterized as having suitably lowlevels of contaminants or antimicrobial component 245 such that thedownstream effluent filtrate 249 is suitable for disposal as plantwastewater discharge in compliance with current effluent guidelines.

In various embodiments, and in further reference to FIG. 23, theantimicrobial separation unit 241 may include a header 250. The header250 is preferably configured to distribute effluent 223, such asupstream or an intermediate downstream effluent filtrate 235, 249,evenly with respect to the filter material 243, however, in at least oneembodiment, the header 250 may be configured to selectively distributethe effluent 223 to one or more regions of the filter material 243within the container 242. The header 250 includes a body 252 defining aninternal fluid path that extends between an upstream inlet 256 and aplurality of downstream fluid ports 258. The body 252 may include one ormore arms 260 into which fluid ports 258 may be formed to distribute theeffluent 223. The arms 260 may include various arrangements of fluidports 258 patterned thereon. In the illustrated embodiment, the header250 includes four arms 160 and may be constructed from piping, forexample, and arranged in a crossing or “X” configuration. In otherembodiments, however, the header 250 may include other configurationswith fewer or additional arms, which may further include secondary arms.

The fluid ports 258 are aligned along two sides of each arm 260.However, in some embodiments, the fluid ports 258 may be aligned along asingle side, circumferentially, or along three or more sides of the arms260 or as otherwise desired to distribute the effluent 223 of effluentfiltrate 235, 249 and reduce channeling. For example, as introducesabove, even distribution may be desirable to prevent channeling or toincrease surface contact between the effluent 223 and the filtermaterial 243. The number and dimensions of the fluid ports 258 may varyto optimize distribution, for example, in consideration of thecharacteristics of the fluid, filter material 243, or flow conditions.As such, the fluid ports 258 may be dimensioned to restrict, direct,spray, or focus the fluid exiting the header 250. As shown, each of thearms includes twenty-six fluid ports 258. In at least one embodiment,each of two or more arms 260 includes twenty fluid ports. As shown, theheader 250 also includes fluid ports 258 having cross-sections between0.125 to 0.250 inches. However, as described above, additionaldimensions and features could also be used depending on the environmentin which the system operates. For example, in one embodiment, the header250 is configured to be movable to increase dispersion of the effluent223. For instance, the header 250 may be adapted to rotate orselectively move according to a pre-determined pattern. The rate ordegree of movement for example may be related to the amount of effluent223 passing through the header.

The header 250 may be employed in a carbon filtration system includingat least two filter units 227 a, 227 b, as described above. It is to beappreciated, however, that filter units 227 a, 227 b do not necessarilyinclude a header 250 or the illustrated header 250. Indeed, in at leastone embodiment, filter units 227 a, 227 b include different headers.Similarly, the filter units 227 a, 227 b may be configured to retain thesame or different filter material 243. In one embodiment, one or both ofthe filter units 227 a, 227 b may include the header 250. As describedabove, the filter units 227 a, 227 b may include containers 242configured to retain filter material 243. The container may include aninner surface 272 or liner 274 configured to be positioned adjacent tothe filter material 243. The header 250 may be suitably positioned at anupstream portion of the container 242 to receive upstream effluentfiltrate 235 or an intermediate downstream effluent filtrate 249, as thecase may be, and therein distribute the fluid onto the filter material243. In the illustrated embodiment, the inlet 256 of the header 250 isconfigured to couple to the downstream capture line 237 to receive theupstream effluent filtrate 235 within the fluid path 254. The header 250is positioned over the filter material 243 and is configured todistribute the upstream effluent filtrate 249 onto the filter material243 positioned within the container 242. In operation, the header 250may be attached to or be positioned within the container 242, which mayinclude a filter drum for example. Distribution provided by the header250 may reduce or inhibit channeling through the container 242. Forexample, the header 250 may distribute or sprinkle received effluent 223or effluent filtrate 235, 249 over a top surface of the filter material243 to thereby achieve increased distribution and little to nochanneling through the filter material 243.

In various embodiments, the antimicrobial separation unit 241 mayinclude a filter unit 227 a, 227 b in which the container 242 includes aplastic or plastic lined drum configured to contain a filter material243 comprising activated carbon. As described above, the filter unit 227a, 227 b may be disposable such that the activated carbon may beproperly disposed of when spent. In contrast to conventional filterunits and containers which are typically formed of metals susceptible tocorrosion, during their operational lifetime in a capture unit 116 theplastic drum may be configured to avoid such corrosion that mayotherwise lead to the occurrence of leaks.

Further examples of capture units 116 controllable by the control system100 is described in U.S. patent application Ser. No. 14/510,385, filedOct. 16, 2014, and titled ANTIMICROBIAL APPLICATION SYSTEM WITH RECYCLEAND CAPTURE, the contents of which are herein incorporated by referencein its entirety.

As introduced above, the control system 100 includes a controller 103configured to execute a monitoring program 120. The monitoring program120 may include various units and modules that may be implemented toprovide the functionalities of the monitoring program 120 includingmodifying the operations of the treatment system 110. The monitoringprogram 120 may include a web application, service, or bundled servicesin which various interfaces 105 such as access devices 142 andnotification devices 144 may interface with the controller 103 andmonitoring program 120. In various embodiments, access devices 142 mayinclude a control panel 138. Access devices 142 may also include localor remote access devices 142 with respect to the operations system 102.Thus, access devices 142 include mobile or remote interfaces configuredto access the controller 103 and the monitoring program 120functionalities via the interface unit 122. In at least one embodiment,access devices 142 and notification devices 144 may interact with thecontroller 103 and monitoring program 120 in a cloud platformenvironment. For example, the various services or applications may beexecuted in a cloud environment through interaction of the devices 138,142, 144 and controller 103. In some embodiments, one or more of thedevices 138, 142, 144 may store the applications in a data storagemedium for execution with a device processor.

As shown, the monitoring program 120 includes an operations unit 121 andan interface unit 122. The operations unit 121 may include a sensormodule 124 configured to collect operation data, an analysis module 126configured to analyze operation data, and an adjustment module 128configured to adjust an operation of the plant operations system 102according to the monitoring program 120, e.g., upon receipt of a controlinstruction from a user or in response to identification ordetermination of a trigger event.

The sensor module 124 may be associated with, e.g., comprise or beoperatively or communicatively coupled with a plurality of sensorsassociated with one or more of the units 112, 114, 116. The sensors maybe positioned at one or more locations to detect and obtain operationdata associated with operational conditions. In various embodiments, theoperation data associated with operational conditions may becommunicated, e.g., transmitted, relayed or routed to, or otherwiseobtained by, the sensor module 124 in real-time. Transmission of theoperation data may be by any manner known in the art, e.g., via wired orwireless communication. For example, in one embodiment, sensors may beconfigured to transmit operation data via a wired or wirelesstransmitter or transceiver configured to transmit the sensed operationdata to the controller 103 for analysis by the sensor module 124. In atleast one embodiment, the sensor module 124 is configured to transmitinstructions to sensors to control initiation, termination, ormodification of sensing activities.

The controller 103 may be configured to receive, transmit, analyze, orprocess operation data. For example, the controller 103, via theanalysis module 126, may be configured to process or analyze operationdata obtained by the sensor module 124. The controller 103 may beconfigured to one or more of obtain, analyze, or transmit operation orother control system data in real-time. For example, the sensor module124 may be configured to obtain operation data for analysis by theanalysis module 126 according to the monitoring program 120. Theanalysis module 126 may be configured to process or analyze, e.g.,measure, count, or quantify operation data as defined in the monitoringprogram 120. In one embodiment, the analysis module 126 is configured toone or more of filter, compile, compare, transmit, route for storage orreporting the operation data. The analysis module 126, via thecontroller 103, may be configured to access the operations database 104or memory unit 107 to obtain control system data such as administrativeparameters for processing or analysis of the operations data. Forexample, the control system data may include historical operation oradministrative data, event logs, administrative parameters such asformulas, statistics, algorithms, or rules accessible by the controller103 to process operation data, e.g., to monitor operational conditionsof the application unit 112, recycle unit 114, or separation unit 116.The controller may be configured to perform statistical analysis ofoperation data and hence operational conditions in real-time. In variousembodiments, analysis of operation data may include the analysis module126 accessing the operations database 104 or memory unit 107 to obtainparameters stored therein for determining or assessing operationalconditions or states of the operations system 102 from the operationdata. The parameters may include predefined set points, statistics,tables, formulas, algorithms, rules, conditional instructions, eventdata, historical or empirical data from which operational conditions maybe determined and assessed from the operation data.

FIGS. 14A & 14B illustrate an exemplary set point table 130 for use in acontrol system 100 configured to monitor and control the antimicrobialapplication system 110 comprising an antimicrobial application unit 112comprising a dip tank. The first column 131 identifies the set pointcondition. The second column 132 identifies a default value of the setpoint. The third and fourth columns 133, 134 identify minimum andmaximum values or allowable range or variation for the set point. Thefifth column 135 provides a quick caption descriptive of the set pointcondition or a related notation. The set points may be stored in theoperation database 104 or memory unit 107 and be accessible by theanalysis module 126. In at least one embodiment, the set points may bestored in a removable storage device that may be coupled with thecontroller 103 for analysis operations. In various embodiments, the setpoints may include dynamic set points such that the defined valuesprovided in the table 130 may change when the analysis module 126identifies one or more specified operational conditions. The controlsystem 100 may include multiple set point tables 130 that may beselected by a user or the analysis module 126 upon the identification ofan operational condition, state, or in response to a trigger event. Asexplained in more detail below, the control system 100 comprises aflexible platform in which users may add, modify, or delete set pointsor set point values. Decision rules or sets of decision rules may alsobe associated with particular set points or set point tables. Forexample, following set point analysis of operational conditions, theanalysis module 126 may be programmed to query administrative decisionrules for characterization of the associated operational state and toinitiate the appropriate response to the trigger event. Theadministrative decision rules may be defined by the user and may bestatic or dynamic, e.g., may be conditional or modifiable by identifiedoperational conditions, states, or other analysis by the analysis module126. In one embodiment, a user may define set points and associateadministrative decision rules with trigger events associated with theset point. The administrative decision rules may define controloperations to modify or tune equipment or operations, notificationconditions, or alarm conditions, for example, in response to particulartrigger events.

With reference again to FIG. 13, in various embodiments, when operationdata or operational conditions are determined to be outside the rangedefined by the minimum and maximum values specified by an applicable setpoint, the analysis module 126 is configured to initiate the definedresponse. For example, the analysis module 126 may be configured togenerate or initiate generation of a notification such as a message orwarning signal. Alternatively or additionally, the analysis module 126may initiate a control operation comprising an adjustment of the plantoperations system 102 via the adjustment module 128. The adjustmentmodule 128 may be configured to adjust operations of the plantoperations system 102. For example, the controller 103 may include or beoperatively associated with operation adjustment devices operable by theadjustment module 126 to modify plant operations, e.g., modulateprocessing rates, speeds, volumes, concentrations, termination orinitiation of processes, etc. In various embodiments, the adjustmentmodule 126 may be operable to activate, deactivate, or modulate plantoperations such as by controlling or initiating operation of pumps,valves, conveyers, or other components or functions of the plantoperations system 102. In at least one embodiment, the analysis module126 may be configured to initiate intervention by the adjustment module128 with respect to the operations of the plant operations system 102automatically, for example, based on a set point defining the occurrenceof one or more trigger events, a predefined schedule, as determined fromanalysis of operation data, such as real-time operation data, ordetermination of operational conditions.

The interface unit 122 may be configured for interfacing the monitoringprogram 120 with interfaces 105, which may include users, access devices142, notification devices 144, or programs. The interface unit 122, forexample, may be configured to interface the monitoring program 120 andits functionalities with a control panel 138, which may be a plantcontrol panel or plant computer. The control panel 138 may be local orremote with respect to the plant operations system 102 and its units112, 114, 116.

The interface unit 122 may also be configured to interface with local orremote access devices 142. The access devices 142 may be configured fortwo-way communication with the interface unit 122 and may includededicated or multi-purposed devices, e.g., tablets, laptops, personalcomputers, smart phones, handheld or mobile electronic communicationdevices, special purpose diagnostic, programming or systemadministration or computational devices, servers, databases, or othercontrollers. Communication between or among the interface unit 122 andthe access devices 142 may be wired or wireless and may includetransmission over one or more networks.

The interface unit 122 may also be configured for one-way communicationwith notification devices 144 or, in some instances, two-waycommunication, such as when it is desirable for the notification device144 to communicate confirmation or a notification or when an accessdevice 142 also includes a notification device 144. Notification devices144 may include access devices 142 or other communication devicesconfigured to receive signals comprising notifications from theinterface unit 122 and initiate an indicator to notify or alert one ormore users to a trigger event. For example, the notification device 144may include or be configured to initiate an indicator such as an audibleor visual alarm, light, text message, telecommunication, email, etc.configured to notify or alert the user. In some embodiments, one or moreof the access devices 142 may comprise a mobile device that maycommunicate with additional access devices 142. For example, an accessdevice 142 may access the monitoring program 120 via the interface unit122 to access the functionalities of the monitoring, e.g., to define ormodify settings of the monitoring program 120 used for monitoring andcontrolling the antimicrobial application system 110. In someembodiments, the access device 142, assuming properly authorized, mayaccess the monitoring program 120 via the interface unit 122 to utilizethe functionalities of the monitoring program 120 and associated systemdevices to directly instruct a change in an operation of theantimicrobial application system 110, e.g., power on or power off pumps,open or close valves, increase antimicrobial component within thetreatment solution, increase transit time or belt speed through the diptank, etc. In one embodiment, access devices 142 may access theinterface unit 122 to communicate with other access devices 142 throughthe monitoring program 120.

As introduced above, the monitoring program 120 may be configured totransmit operation data, plant or operational conditions, notifications,alters or other data, which may include historical, real-time, orprojected data, for example, to the various interfaces 105. Theinterface unit 122 may also be configured to receive new or updatedadministrative parameters such as set points or values, algorithms,statistics, administrative decision rules such as alarm conditions,notification definitions or instructions such as updated securitydefinitions.

The interface unit 122 may also be configured to receive monitoringprogram 120 settings or system updates from users, programs, orapplications via access devices 142 or the control panel 138. In oneembodiment, the interface unit 122 is configured to proactively sendcontrol system data to access devices 142, users, or groups of users.The interface unit 122 may also be configured to receive requests fromauthorized users or access devices 142 for specified control systemdata. For example, requests may be for event logs, historical data,analyses of operational conditions, reports with respect to one or moreoperational conditions over specified operational periods. The interfaceunit 122 may also receive requests or instructions from users, accessdevices 142, programs, applications, or services for initiation ortermination of various activities of the adjustment module 128configured to adjust the operation of the plant operations system 102.For example, the interface unit 122 may receive operation controlinstructions from authorized users to view, modify, update, or overrideoperations or states of the control system 100 or operations system 102,such as the antimicrobial application system 110.

In certain embodiments, the monitoring program 120 may communicatesignals to one or more notification devices 144 to provide anotification reflecting an state, activity, or function of theoperations system 102. For example, one such notification may betransmitted by the interface unit 122 at the direction of the analysismodule 128 in response to a trigger event. The notification may be sentto one or more notification devices 144 to include an alert, warninglight, or graphical display. In various embodiments, notifications mayinclude emails, phone calls, text messages or alarms.

FIG. 15 depicts an operation of the monitoring program 120 according tovarious embodiments. At 170, the sensor module 124 obtains operationdata. At 171, the analysis module 126 analyzes the operation data todetermine an operational condition 172. The analysis may includeanalysis of the operation data in a raw form or may include processingthe raw operation data as described herein. For example, the analysismodule 126 may access and apply administrative parameters, which mayinclude rules, statistics, algorithms, historical data, etc. configuredto generate or transform the raw operation data into an operationalcondition format. At 173, the analysis module 126 compares theoperational condition 172 to set points to determine an administrativestate 174. At 175, the analysis module 126 queries the administrativedecision rules to determine if the administrative state 174 ischaracterized as a trigger event 176. If the administrative decisionrules do not characterize the administrative state 174 as a triggerevent 177, the analysis module 126 may take no specific action inresponse or may apply a default response such as recording or routingthe data or analysis to the operations database 104 for archiving orlater analysis. If the administrative state 174 is characterized as atrigger event 178, the analysis module identifies the appropriateresponse 179 specified by the administrative decision rules. Forexample, application of the administrative decision rules may identifythat no action is required in response to the state. The responseinitiated at 179 may vary depending on the trigger event to be addressor as otherwise defined by the user but may include generating orissuing a notification, such as an alarm or message, to a user, accessdevice 142, notification device 144, or specified combination thereof,generating an event log or report identifying the state, time stampingand archiving the state or related operation data, transmitting thestate to a multi-plant controller or remote monitoring program orinitiating a control operation to modify the operation of one or moreaspects of the antimicrobial application system 110 as described herein.

In one embodiment, the sensor module 124 may be configured to obtainoperation data related to work piece detection. Work piece detection mayinclude one or more sensors configured to detect work pieces, e.g.,optically, by weight, by transit time, etc. For example, in oneembodiment, the sensor module 124 may be associated with one or moreelectronic eyes that may be used in connection with managingconcentration of antimicrobial treatment solution. An electronic eye oran array of electronic eyes may be used to detect the presence, number,orientation, or rate, for example, of work pieces processed by theapplication unit 112. In one instance, the electronic eye or array ofelectronic eyes is configured to detect work pieces positioned on orsuspended from conveyer belts or hooks, such as shackle lines, orsubmerged in antimicrobial treatment solution. Upon sensing theoperation data, the sensor module 124 may provide some or all of theoperation data to the analysis module for analysis of one or moreoperational conditions.

In various embodiments, operational conditions analyzed may be theoperation data sensed or measured or may be a condition directly orindirectly derived from the operation data sensed or measured. Forexample, the number of work pieces in which the antimicrobial treatmentsolution has been applied may be a variable in an algorithm used by theanalysis module 126 to determine an expected concentration ofantimicrobial component alone or in combination with other operationdata or analyzed operational conditions. For example, configurations ofoptical sensors comprising electronic eyes may be used by the sensormodule 124 to detect work pieces processed or transported along aconveyor belt for processing. The conveyor belt may include a reflectoron one side. Work pieces may be detected when obstructing a path orsightline between an electronic eye and a reflector. Upon obtaining orreceiving the operation data, the analysis module 124 may be configuredto analyze the operation data and take into account the presence of beltfeatures (e.g., flights) that may project outward of the belt surface.For example, the size, number, transit time, or expected location of thebelt features may be calculated and filtered from raw operation data.The filtered operation data may then be analyzed for indirectdetermination of antimicrobial concentration, which in some embodimentsmay be incorporated into an algorithm applied by the analysis module126, the set points, or the administrative decision rules. Otheroperation data may also be useful to determine the concentration of theantimicrobial treatment solution such as the weight the pre and posttreated work pieces downstream and upstream of the application area.

In some embodiments, it is desirable to add a food-grade defoamingsolution to an antimicrobial treatment solution comprising CFC duringthe recycling process. Thus, in various embodiments, the analysis module126 may be configured to initiate the adjustment module 128 to dose theantimicrobial treatment solution with a defoamer. The timing and amountof the dosing may be in response to a trigger event. The administrationprogram 120, for example, may include administrative parametersincluding an algorithm executable by the controller 103, via theanalysis module 126, to direct a periodic add of a defoaming solution toblend into the antimicrobial treatment solution in response to a triggerevent. In one embodiment, periodic addition of the defoaming solutionmay be automated according to the administrative decision rules definedin monitoring program 120 to manage the volume of the defoamingcomponent in the antimicrobial treatment solution in real-time. Forexample, the analysis module 126 may respond to a trigger event byinitiating the adjustment module 128 to add an appropriate dose ofdefoamer according to a predetermined set of outcomes determined fromthe analysis of the operation data, which may include comparison of setpoints and operational conditions identified by the analysis module 126.

The set points may define preparation of antimicrobial treatmentsolution such that the adjustment module 128 may initiate addition of avolume of water and antimicrobial component to a dip tank or othersolution reservoir or line. That is, the adjustment module 128 mayperform a control operation comprising a controlled addition of anantifoaming agent to the solution of water and antimicrobial componentdesigned to obtain a target concentration. This may be done based upon apredefined administrative state determined by the analysis module 126 bycomparison to one or more predefined set points. The targetconcentration may be, for example, 0.8% or 0.6% antifoaming agent byweight. The initial concentration may be determined according to thedefault set point value 132. During operation, the concentration maydeviate from the default value 132 and thus this operational conditionmust be monitored by the operations unit 121. When operation data oranalysis of operation data determines operational conditions are suchthat the concentration of defoamer or antimicrobial component is outsidethe minimum/maximum 133/134 range, the analysis module 126 may initiateaddition of defoamer or antimicrobial component. As described above, thedetermination may be based in part on the number of work pieces treatedand thus may incorporate historical operation data, statistics, oralgorithms in conjunction with real-time data to indirectly determinesolution composition.

As introduced, above, the control system 100 may include a control panel138 for interfacing with the controller 103 and monitoring program 140of the controller 103 via the interface unit 122. FIG. 16 illustratesone configuration of a control panel 138. The control panel 138 includesa graphical user interface 150 for displaying information related to theoperation of the plant operations system 102 or control system 100. Thecontrol panel also comprises various peripherals such as selectiondevices 151 and indicators 152. As shown, the selection devices 151include a touch screen 153, switches 154, and buttons 155. Otherselections devices 151 may also be used, e.g., mouse, pointer, keyboard.One or more of the switches 154 or buttons 155 may comprise a hardbutton or soft button that may be selectively programmed according touser preference. The selection devices 151 may be configured to allowusers to interface with the operations of the monitoring program 140 ofthe controller 103 to view, define, or modify operation conditions orset points. The selection devices 151 may also be configured to allowusers to manually instruct the controller 103 to perform a controloperation or override a control operation.

The indicator 152 may generally include media or mass communicationdevice. As shown, the indicator 152 comprises light 156, however,additional or different devices such as speakers and, in some instances,text displays may be additionally or alternately used. The light 156 maybe activated during specified operations of the operational system ormay be used to indicate an operational condition, the occurrence of atrigger event, a warning, a pending notification, or for another reasondefined in the monitoring program 120 or a control panel application.The indicator 152 may be programmed for multiple indication tasksdefined by various operational states, e.g., multiple flashingsequences, to provide indicator capabilities for multiple situations. Itis to be appreciated that the indicator 152 may be optional or may belocated separate from the control panel 138. Indeed, in someembodiments, multiple indicators 152 may be located throughout the plantto provide notifications to users. The particular indicator 152 andmanner or indication may be customized by the user. The user may alsocustomize the notifications to identify one or more particular events orconditions as well as degrees of such events or conditions.

The control panel 138 may include a wired or wireless data orcommunication port 157 into which a user may couple a local or remoteuser access device 142 such as a computer, tablet, notebook, smartphone, mobile communication device, programming card, flash drive,memory stick, or special purpose diagnostic, programming, or systemadministration device. For example, in one embodiment, the control panel138 includes a data port configured to receive a data storage devicesuch as a flash drive defining one or more set points, administrativeparameters, or security definitions. In some embodiments, thecommunication port 157 of the control panel 138 provides an access pointto user access devices 142 to access the monitoring program 120 and itsfunctionalities.

The control panel 138 may be located locally with respect to the plantoperations system 102, e.g., on the line or production floor. Thecontrol panel 138 may provide users with a local access point to thecontrol system 100. In one configuration, the control panel 138 includesa processor, memory, and communication port. The memory may store acontrol panel application configured to be executed by the processor andinterface the user with the monitoring program 120. In variousembodiments, the control panel 138 integrates with the processing, datastorage, and communication functionalities of the controller 103 andmonitoring program 120. The control panel 138 may be integrated with orin addition to a plant computer. In various configurations, users mayuse the control panel 138 to update or modify set points, initiateadjustments via the adjustment module 128, query the operations database104 or analysis module 126 for operation data or analysis, e.g., togenerate or define reports, view event logs, historical or projectedperformance, or real-time operation data or operational conditions,which may include interfacing with the sensor module 124 to initiatecollection of real-time operation data. The control panel 138 may alsoallow users to access, define, or modify security features such aspermissions or user access levels, perform administrative tasks,override automated operations, or initiate, terminate, or modifyoperations.

FIG. 17 is a screen shot of the graphical user interface 150 accordingto various embodiments. The graphical user interface 150 includesidentification of a mode of operation and specifies that the currentmode is RUN or in operation. The graphical user interface 150 alsoidentifies the time until the next scheduled addition of antimicrobialcomponent and the state of the pump positioned to add the antimicrobialcomponent. The graphical user interface 150 also identifies the targetconcentration and dwell time of the work pieces within the dip tank, thestate of a photo eye sensor configured to detect work pieces, and thevolume level of antimicrobial treatment solution within the dip tank.The graphical user interface 150 also provides an alert status, which isshown as no alerts pending. As described above, the graphical userinterface 150 may include a touch screen interface. As shown, thegraphical user interface 150 includes a menu selection wherein a usermay touch the screen to pull up a control panel menu.

FIG. 18 is another screen shot of the graphical user interface 150showing a menu screen for use with a dip tank application identifyingset points and their administrative states, as detected by the sensormodule 124 and analyzed by the analysis module 126, corresponding torows 57-62 of the set point table 130 of FIGS. 14A & 14B and identifiedby the English captions provided in column 135. Thus, a user may use thecontrol panel 138 to view the current state of multiple aspects of theplant operations system 102 in real-time. In one embodiment, the usermay select one of the identified set points to view or change the valuesdefining the current set points. Typically, it will be preferable torequire the user to establish authorization, e.g., by providing anidentification or authorization code, before allowing the user to modifycertain or any set point definitions or values.

As introduced above, the interface unit 122 may interface withnotification devices 144 or access devices 142, which may includenotification devices 144. Access devices 142, for example, may beconfigured to interact with the monitoring program 120 via accessapplications. Access applications may include one or more servicesthough which access devices 142 or users of access devices 142 mayinteract with or utilize the monitoring program 120 functionalities.Access applications may be stored in-whole or in-part in data storagemediums associated with one or more access devices 142, the controller103, the operations database 104, a control system 100 network, cloud,or other accessible location. Access applications may be configured tobe executed by processors operatively associated with control systemdevices such as access devices 142, the controller 103, or operationsdatabase 104, e.g., an access application may be executed in-part by aremote processor for simulation on an access device 142. Accessapplications may include browsers configured to interact with one ormore monitoring program 120 access applications or services, which maybe bundled and purposed for the user according to the user's accesslevel.

In various embodiments, the monitoring program 120 includes a pluralityof user access levels to ensure security and integrity of the controlsystem 100. User access levels may be used to control access to thecontroller 103, monitoring program 120, and associated functionalities.Access levels may be associated with monitoring program 120 services orfunctionalities available to access devices 142 or users. For example,the monitoring program 120 may include ten access levels comprisingvarious combinations of permissions to view, access, or modifyoperations of the plant operations system 102, e.g., read or editcurrent set point settings or detected states, override automationparameters or functions, initiate system responses to trigger events orbring particular systems on or offline. The combination of permissionsgranted to each access level may be limited by user authorization oraccess device 142 and therefore may provide different functionalitiesfor different users or access devices 142. Access applications may beconfigured to present user profiles, security credentials, orcertificates that define the level of access and monitoring program 120functionalities available to a user, e.g., actions or informationavailable to a user using the application. Access levels may vary bylocation of the access device, manner of interface, e.g., type ofdevice, connection protocol, network path, format, or identity of theuser. In one configuration, the interface unit 122 is configured toverify users, e.g., verification of credentials, permissions, orclearances of users as defined in the monitoring program 120. Users maybe required to provide identifying data such as a password, deviceinformation, or location.

In various embodiments, access applications may include monitoringprogram 120 services comprising one or more administrativefunctionalities. Administrative functionalities may be configured toprovide access to one or more controllers 103 or operations databases104. Various levels of administrative functionalities may includedefining or modifying set points, setting permissions, security levels,specifying notification or alert criteria, identifying applicable usersor devices to be notified or alerted, manner of providing notificationssuch as text message, email or alarm.

In some embodiments, access applications may include monitoring program120 services comprising one or more operation control functionalitiesconfigured for modifying the operation of the plant operations system102. Various levels of operation control functionalities may includeinitiating, terminating, or modifying operations of the operationssystem 102 such as opening or closing valves and powering pumps on andoff, and overriding administrative parameters or control operationinstructions.

In certain embodiments, access applications may include monitoringprogram 120 services comprising one or more monitoring functionalitiesconfigured for monitoring the operations of the operations system 102 ofone or more plants and may include access to one or more controllers 103or operations databases 104. Various levels of monitoringfunctionalities may include access to the operations database 104 toview archived operation data, event logs, or performance and viewingreal-time operation data or current states. The interface unit 122 mayalso be configured to transmit requested data, responses, confirmations,or data related to monitoring functions. Periodic, continuous,scheduled, or conditional data transmissions may be specified fortransmission to access devices 142. The type and timing of the datatransmissions may be defined by the user in accordance with themonitoring functionalities provided by the access application or may bedefined at another access device 142, plant computer, or control panel138. Monitoring functionalities may include transmissions of operationdata or operational analysis. Monitoring functionalities may alsoinclude receiving transmissions of updates, notifications, such asalerts or alarms at an access device 142. For example, the analysismodule 126 may be configured to identify various operational conditions,e.g., by performing operational condition analyses of operation data,and the interface unit 122 may be configured to transmit a notificationsuch as an alert or alarm to specified access devices 142 ornotification devices 144 associated with a user or group of users, e.g.,using messaging services, text messages, prerecorded messages, pages,email. The notification may identify a type or level of alert, anadministrative state or trigger event prompting the notification, apotential cause, etc. In one embodiment, the notification may identify aproposed solution. The proposed solution may be pre-defined to allow auser to quickly address the event. In one embodiment, for example, thenotification provides one or more “one click” solution buttons that maybe selected by the user to initiate a predefined response such astransmission of a control instruction to the adjustment module toinitiate control operation to modify operation of the operations system102, such as the antimicrobial application system 110. The notificationmay include a recent operation activity log relevant to the event oridentify other users or access devices 142 receiving the notification orsteps taken by such uses or access devices 142 to address the subjectmatter of the notification. The notification may also include acommunication link to transmit messages or additional notifications toother users or access devices 142.

Access applications may also include one or more corporatefunctionalities. Corporate functionalities may be configured for use bycorporate users and thus provide one or more levels of monitoringfunctionalities. The monitoring functionalities for corporate users maybe modified to provide a broader overview of plant performance and mayinclude the ability to generate or specify plant performance reports. Inone embodiment, the corporate functionalities include access to plantperformance reports from multiple plants, for example, via access tomultiple operations databases 104, or to performance analyses frommultiple plants compiled by the analysis module 126.

FIGS. 19 and 20 schematically illustrate two embodiments of the controlsystem 100 in which the system 100 is configured for centralizedmonitoring and control of operations systems comprising an antimicrobialapplication system and associated units (not shown, see, e.g., FIG. 13).The control system 100 may be similar to the control system 100described above where like features are similarly identified. Thus, themonitoring program 120 may comprise a plant monitoring program 220 a,220 b and a multi-plant monitoring program 320 that may independentlyinclude or share the functionalities described above with respect to themonitoring program 120.

Each plant may comprise a plant controller 203 a, 203 b configured tocollect operation data associated with the antimicrobial applicationsystem, e.g., an antimicrobial application unit, and is operable tocontrol operations of the plant operations system. The multi-plantcontroller 303 may comprise a server such as a communication server andmay be configured for real-time data routing and database storage. Thefirst plant controller 203 a and the second plant controller 203 b areconfigured to transmit operation data to the multi-plant controller 303.The operation data may include real-time data. In one embodiment, eachplant controller 203 a, 203 b is configured to transmit real-timeoperation data to the multi-plant controller 303 at scheduled intervals,such as every second or other specified time, upon request, or upon theoccurrence of a trigger event. As described above, using access devices142, set points may be remotely modified over an internet connection.The control system 100 may therefore include a distributed networkarchitecture having a centralized server comprising the multi-plantcontroller into which the plant controllers 203 a, 203 b and accessdevices 142 remotely connect to interface with the operations of theantimicrobial application system.

The multi-plant monitoring program 320 and plant monitoring programs 220a, 220 b may be configured to coordinate operations, communications, andvarious administrative tasks. Users may customize settings and thefunctionalities accessible via interfacing access devices 142 andnotification devices 144 to suit the user's desired application.Operation data transmission may be wired or wireless depending on theapplication. As shown, the operation data is transmitted from eachcontroller 203 a, 203 b to the multi-plant controller 303 over adistributed network. The transmissions may be transmitted through thefire wall/router 260 a, 260 b, 360 a of each plant and the multi-plantcontroller 303, as shown in FIG. 19. For example, the data may betransmitted using an internet or telecommunications connection.

The multi-plant controller 303 may include or maintain a multi-plantoperations database 304, which may or may not include, in whole or inpart, individual plant operations databases 204. The multi-plantoperations database 304 may archive, log, or maintain operation data andrelated analysis, store generated statistics or reports, or provideaccess to individual or multi-plant statistics. The multi-plantoperations database 304 may also provide access to historical operationdata, analysis, event logs, etc. or provide such information forgeneration of single or multi-plant reports.

Referring to FIG. 19, the notification device 144 and access devices 142a, 142 b may be in one or two-way communication with the multi-plantcontroller 303, which may include communications transmitted betweenfirewalls/routers 160 a, 160 b, 260. Notably, with respect to the plantoperations system, the access devices 142 a, 142 b or notificationdevices 144 are not limited by a local or remote location. For example,a user may access the multi-plant monitoring program 320 (see FIG. 20)at an access device 142 a, 142 b) or receive notifications at anotification device 144 whether the user or device 142 a, 142 b, 144 ison the plant floor or offsite. Thus, the multi-plant controller 303 maybe configured as a central point from which data may be routed andoperations may be controlled.

Access device 142 a may be configured for use by a service technicianuser 140 a. Depending on the access level of the access device 142 a oruser 140 a, access device 142 a may include or have access to one ormore access application services having monitoring, operation control,or administrative functionalities as described above. For example, theuser 140 a of access device 142 a may perform or define plant monitoringoperations, set, define, or receive notifications such as real-timenotifications, alerts, or alarms, define user access levels or performother user administration tasks, or otherwise set or modify systemsettings. For example, an engineer located remotely may be provided withaccess to one or more plants, which may be located anywhere in theworld. Using the control system 100 the engineer may remotely change andadjust the operation of the antimicrobial application system. Thus, theengineer may obtain real-time operation data and modulate operation andadministrative parameters in real-time.

Access device 142 b may be configured for use by a corporate user 140 b.Depending on the access level of the access device 142 b or user 140 b,access device 142 b may include or have access to one or more monitoringfunctionalities as described above. For example, the user 140 b ofaccess device 142 b may view or receive plant performance history ordefine performance report criteria or frequency with respect to one ormultiple plants.

Notification device 144 may be configured for use by a notification user140 c to receive notifications as defined in the monitoring program 220a, 220 b of one or both plants or the multi-plant monitoring program320, which may include a dedicated plant monitoring program for eachplant. Notifications may include alarms, text messages, emails, etc., asdescribed above. Notifications received at notification devices 144configured for two-way communication may allow the user to respond tothe notification or transmit a confirmation to the multi-plantcontroller 320 of receipt or read of the notification.

The multi-plant monitoring program 320 may be configured to handlecontrol system data, e.g., route, store, or process operations data,analyze operational conditions, generate reports, event logs,notifications, etc. The multi-plant monitoring program 320 may include,replace, integrate, or be configured to interface with the plantmonitoring program 220 a, 220 b. The multi-plant administration program320 may be configured to provide remote monitoring and controlfunctionalities, some of which may overlap or be in addition to those ofthe plant monitoring program 220 a, 220 b. In one embodiment, the plantmonitoring program 220 a, 220 b provides local control and monitoringfunctions, e.g., using a control panel, which may be similar to controlpanel 138 described above.

The plant controller 203 a may submit control instructions received fromthe multi-plant controller 303, which may be in addition to or differentfrom control instructions provided by the analysis module 226 a. In atleast one embodiment, the plant controller 203 a may be selectivelyconfigurable to operate as a slave controller and the multi-plantcontroller 303 is selectively configurable to operate as the mastercontroller to direct or override the operation of the plant controller203 a.

In various embodiments, the multi-plant controller 303 may function as acentral monitoring or control service for multiple plants, anintermediate service for remote monitoring or control of individualplants, a plant oversight service, or a plant startup or auditingservice, for example. It is to be appreciated that the level of serviceprovided by the multi-plant controller 303 to each plant may not be thesame. For example, the multi-plant controller 303 may provide monitoringservice for a first plant and monitoring and control service for asecond plant.

As introduced above, the plant monitoring program 220 a, 220 b and themulti-plant monitoring program 320 may independently include or sharefunctionalities. Referring to FIG. 20, the plant controller 203 a, 203 bincludes a monitoring program 220 a, 220 b, which may be similar to themonitoring program 120 described above with respect to FIG. 13, and anoperations unit 221 a, 221 b. The operations unit comprises a sensormodule 224 a, 224 b operatively coupled to a plurality of sensors toreceive operation data. The monitoring program 220 a of the plantcontroller 203 a may also include an analysis module 226 a to analyzeoperation data according to the monitoring program 220 a. Themulti-plant controller 303 includes a multi-plant monitoring program 320comprising an operation unit 321 and an interface unit 322. In thisconfiguration, the interface unit 222 a, 222 b of the plant monitoringprogram 220 a, 220 b transmits operation data, notifications, states,trigger events, event logs, or other data to the interface unit 322 ofthe multi-plant program 320. The multiple-plant controller 303 mayanalyze the data using a multi-plant analysis module 326 to determine ifoperational conditions are within set points. As described above, theset points may be static or dynamic. Thus, the multi-plant controller303 may perform an initial or second data analysis, as the case may be.In other embodiments, the analysis of the operation data is distributedbetween the plant monitoring program 220 a, 220 b and the multi-plantmonitoring program 320, e.g., based on available resources or asotherwise desired. The multi-plant controller 303 and monitoring program320 may provide oversight functions for the control system 100 withrespect to one or more plant controllers 203 a, 203 b or operationthereof. The multi-plant analysis module 326 of the multi-plantcontroller 303 may also perform data analysis functions for the plantcontroller 203 b. The multi-plant interface unit 322 may also transmitnotifications and provide access to interfaces 305 which may be inaddition to or instead of transmission of notifications or accessprovided to interfaces 222 a, 222 b by the plant interface unit 222 a.

Plant controller 203 b includes monitoring program 220 b configured withan interface unit 222 b and an operations unit 221 b. The operationsunit comprises a sensor module 224 b, and an adjustment module 228 b.The interface unit 222 b is configured to transmit operation dataobtained by the sensor module 224 b to the multi-plant interface unit322 for analysis by the multi-plant analysis module 326. The multi-plantanalysis module 326 may be configured to analyze the operation data andrespond using administrative decision rules similar to that describedabove with respect to analysis module 126. The multi-plant analysismodule 326 may be configured to generate reports or files, updatepreviously generated reports or files, and store or distribute thereports, files, or updated reports or files. The multi-plant analysismodule 326 may be configured to provide analysis, reports, andnotifications, e.g., alerts or warnings, to interfaces 305 such asaccess or notification devices 142, 144, via the interface unit 322. Themulti-plant interface module 322 may also be configured to route to theadjustment module 228 b, or in some embodiments to the adjustment module228 a, control operation instructions received from authorized users oraccess devices 142 or from the multi-plant analysis module 326 inresponse to a trigger event, e.g., as defined by administrative decisionrules.

The foregoing description of various embodiments of the presentinvention is provided to enable any person skilled in the art to makeand use the present invention and its embodiments. Various modificationsto these embodiments are possible, and the generic principles presentedherein may be applied to other embodiments as well.

It will be apparent to one of ordinary skill in the art that some of theembodiments as described hereinabove may be implemented in manydifferent embodiments of software, firmware, and hardware in theentities illustrated in the figures. The actual software code orspecialized control hardware used to implement some of the presentembodiments do not limit the present invention.

As used herein, a “computer” or “computer system” may be, for exampleand without limitation, either alone or in combination, a personalcomputer (PC), server-based computer, main frame, server, microcomputer,minicomputer, laptop, personal data assistant (PDA), cellular phone,pager, processor, including wireless and/or wireline varieties thereof,and/or any other computerized device capable of configuration forreceiving, storing and/or processing data for standalone applicationand/or over a networked medium or media. For example, variousembodiments may include access devices or be configured to communicate,e.g., transmit data or interface, with the control system and program asdescribed herein.

Computers and computer systems described herein may include operativelyassociated computer-readable memory media such as memory for storingsoftware applications and instructions used in obtaining, processing,storing and/or communicating data. It can be appreciated that suchmemory can be internal, external, remote or local with respect to itsoperatively associated computer or computer system. Memory may alsoinclude any means for storing software or other instructions including,for example and without limitation, a hard disk, an optical disk, floppydisk, DVD, compact disc, memory stick, ROM (read only memory), RAM(random access memory), PROM (programmable ROM), EEPROM (extendederasable PROM), and/or other like computer-readable media.

Some embodiments may be implemented, for example, using amachine-readable medium or article which may store an instruction or aset of instructions that, if executed by a machine, may cause themachine to perform a method and/or operations in accordance with theembodiments. Such a machine may include, for example, any suitableprocessing platform, computing platform, computing device, processingdevice, computing system, processing system, computer, processor, or thelike, and may be implemented using any suitable combination of hardwareand/or software. The machine-readable medium or article may include, forexample, any suitable type of memory unit, memory device, memoryarticle, memory medium, storage device, storage article, storage mediumand/or storage unit, for example, memory, removable or non-removablemedia, erasable or non-erasable media, writeable or rewriteable media,digital or analog media, hard disk, floppy disk, Compact Disk Read OnlyMemory (CD-ROM), Compact Disk Recordable (CD-R), Compact DiskRewriteable (CD-RW), optical disk, magnetic media, various types ofDigital Versatile Disk (DVD), a tape, a cassette, or the like. Theinstructions may include any suitable type of code, such as source code,compiled code, interpreted code, executable code, static code, dynamiccode, and the like. The instructions may be implemented using anysuitable high-level, low-level, object-oriented, visual, compiled and/orinterpreted programming language, such as C, C++, Java, BASIC, Perl,Matlab, Pascal, Visual BASIC, assembly language, machine code, and soforth. The embodiments are not limited in this context.

It can be appreciated that, in certain aspects, a single component maybe replaced by multiple components, and multiple components may bereplaced by a single component, to provide an element or structure or toperform a given function or functions. Except where such substitutionwould not be operative to practice certain embodiments of the presentinvention, such substitution is considered within the scope of thepresent invention.

The control system and operations system, which may include anantimicrobial application system, has been illustrated and described ascomprising several separate functional elements, such as modules orunits. Although certain of such modules or units may be described by wayof example, it can be appreciated that a greater or lesser number ofmodules or units may be used and still fall within the scope of theembodiments. Further, although various embodiments may be described interms of modules or units to facilitate description, such modules orunits may be implemented by one or more hardware components (e.g.,processors, DSPs, PLDs, ASICs, circuits, registers, servers, clients,network switches and routers), software components (e.g., programs,subroutines, logic) and/or combination thereof.

In various embodiments, the control system or application system,including antimicrobial application equipment, may comprise multiplemodules connected by one or more communications media. Communicationsmedia generally may comprise any medium capable of carrying informationsignals. For example, communications media may comprise wiredcommunications media, wireless communications media, or a combination ofboth, as desired for a given implementation. Examples of wiredcommunications media may include a wire, cable, printed circuit board(PCB), backplane, semiconductor material, twisted-pair wire, co-axialcable, fiber optics, and so forth. An example of a wirelesscommunications media may include portions of a wireless spectrum, suchas the radio-frequency (RF) spectrum. The embodiments are not limited inthis context.

The modules or units may comprise, or be implemented as, one or moresystems, sub-systems, devices, components, circuits, logic, programs, orany combination thereof, as desired for a given set of design orperformance constraints. For example, the modules may compriseelectronic elements fabricated on a substrate. In variousimplementations, the electronic elements may be fabricated usingsilicon-based IC processes such as complementary metal oxidesemiconductor (CMOS), bipolar, and bipolar CMOS (BiCMOS) processes, forexample. The embodiments are not limited in this context

Unless specifically stated otherwise, it may be appreciated that termssuch as “processing”, “generating”, “calculating”, “determining”,“analyzing” or the like, refer to the action or processes of a computeror computing system, or similar electronic computing device, thatmanipulates or transforms data represented as physical quantities (e.g.,electronic) within the computing system's registers or memories intoother data similarly represented as physical quantities within thecomputing system's memories, registers or other such informationstorage, transmission or display devices. The embodiments are notlimited in this context. An action such as “identifying” when performedby a computer or computer system may include identification bydetermining, accessing system data, comparisons with system data,instructions, or the like. An action such as initiating may includecausing an event or thing initiated either directly or indirectly. Forexample, initiating may include signaling, providing power orinstructions, physical manipulation, transmission of data, calculationof conditions, or other step resulting in the event sought to beinitiated. Furthermore, an action such as “storing”, when used inreference to a computer or computer system, refers to any suitable typeof storing operation including, for example, storing a value to memory,storing a value to cache memory, storing a value to a processorregister, and/or storing a value to a non-volatile data storage device.Various embodiments are described and illustrated in this specificationto provide an overall understanding of the composition, function,operation, and application of the disclosed system, apparatus andmethods. It is understood that the various embodiments described andillustrated in this specification are non-limiting and non-exhaustive.Thus, the invention is not necessarily limited by the description of thevarious non-limiting and non-exhaustive embodiments disclosed in thisspecification. The features and characteristics illustrated or describedin connection with various embodiments may be combined with the featuresand characteristics of other embodiments. Such modifications andvariations are intended to be included within the scope of thisspecification. As such, the claims may be amended to recite any featuresor characteristics expressly or inherently described in, or otherwiseexpressly or inherently supported by, this specification. Further,Applicant reserves the right to amend the claims to affirmativelydisclaim features or characteristics that may be present in the priorart. Therefore, any such amendments comply with the requirements of 35U.S.C, §§ 112(a) and 132(a). The various embodiments disclosed anddescribed in this specification can comprise, include, consist of orconsist essentially of the features and characteristics as variouslydescribed in this specification.

Any patent, publication, or other disclosure material identified in thisspecification is incorporated by reference into this specification inits entirety unless otherwise indicated, but only to the extent that theincorporated material does not conflict with existing descriptions,definitions, statements, or other disclosure material expressly setforth in this specification. As such, and to the extent necessary, theexpress disclosure as set forth in this specification supersedes anyconflicting material incorporated by reference into this specification.Any material, or portion thereof, that is said to be incorporated byreference into this specification, but which conflicts with existingdefinitions, statements, or other disclosure material set forth in thisspecification, is only incorporated to the extent that no conflictarises between that incorporated material and the existing disclosurematerial. Applicants reserve the right to amend this specification toexpressly recite any subject matter, or portion thereof, incorporated byreference into this specification.

The grammatical articles “one”, “a”, “an”, and “the”, as used in thisspecification, are intended to include “at least one” or “one or more”,unless otherwise indicated. Thus, the articles are used in thisspecification to refer to one or more than one (i.e., to “at least one”)of the grammatical objects of the article. By way of example, “acomponent” means one or more components, and thus, possibly, more thanone component is contemplated and may be employed, or used in animplementation of the described embodiments. Further, the use of asingular noun includes the plural, and the use of a plural noun includesthe singular, unless the context of the usage requires otherwise.

The matter set forth in the foregoing description and accompanyingdrawings is offered by way of illustration only and not as a limitation.While the systems, methods, compositions, and devices for recycling ofantimicrobial treatment solution have been described and illustrated inconnection with certain embodiments, many variations and modificationswill be evident to those skilled in the art and may be made withoutdeparting from the spirit and scope of the disclosure. For example, thesystems, methods, compositions, and devices disclosed herein have beenidentified, adapted to, and designed for food processing use, andparticularly to processing of chicken and other poultry parts. Thosehaving skill in the art will understand upon reading the presentdisclosure that the subject matter may be applied to other processinguses. The disclosure is thus not to be limited to the precise details ofmethodology or construction set forth above as such variations andmodification are intended to be included within the scope of thedisclosure.

What is claimed is:
 1. A control system for monitoring operations ofantimicrobial application equipment of an application treatment system,the control system comprising: a controller configured to execute amonitoring program comprising an operations unit and an interface unit,the operations unit comprising: a sensor module operatively coupled to aplurality of sensors positioned to detect real-time operation dataassociated with operation of the antimicrobial application equipment, anadjustment module operatively coupled to the antimicrobial applicationequipment and configured to adjust the operation of the antimicrobialapplication equipment, and an analysis module configured to analyze thereal-time operation data and initiate a specified response when theanalysis indicates that a trigger event has occurred, wherein theresponse comprises at least one of issuing a notification to one or morenotification devices or initiating the adjustment module to perform acontrol operation to modify the operation of the antimicrobialapplication equipment; and wherein the antimicrobial applicationequipment comprises one or more components selected from the groupconsisting of: a rotary screen filter comprising a rotatable,cylindrical body defined by a screen and into which antimicrobialtreatment solution is received for filtration of solid components; aplurality of spray nozzles positioned to direct antimicrobial treatmentsolution onto work pieces as the work pieces are conveyed through aspray cabinet; a dip tank for containing antimicrobial treatmentsolution and a conveyer for conveying work pieces through theantimicrobial treatment solution contained in the dip tank; a suctionbox configured to fluidically couple to a dip tank and including asensor for sensing a level of antimicrobial treatment solution in thedip tank; a capture unit comprising a series of activated carbon filtersto filter antimicrobial component from an antimicrobial treatmentsolution; and a capture unit comprising a series of activated carbonfilters each including a header having a plurality of arms definingfluid ports for distributing antimicrobial treatment solution over theactivated carbon.
 2. The control system of claim 1, wherein thenotification comprises one of an audible alarm, visual alarm, textmessage, and email.
 3. The control system of claim 1, wherein analysisof the real-time operation data comprises a comparison of the real-timeoperation data or an operational condition derived therefrom with a setpoint pre-defined in the monitoring program.
 4. The control system ofclaim 3, wherein the set point comprise one of depth of antimicrobialtreatment solution in a dip tank, depth of work pieces submerged in thedip tank during treatment, duration of treatment of work pieces conveyedthrough the dip tank, number of work pieces treated, and agitation jetpressure supplied to the dip tank.
 5. The control system of claim 1,wherein the controller comprises a plant controller and a multi-plantcontroller, wherein the multi-plant controller is configured to remotelymonitor and control operations of multiple anti-microbial treatmentsystems, wherein the plant controller comprises the sensor module andthe adjustment module and the multi-plant controller comprises theanalysis module, and wherein the plant controller is configured totransmit the real-time operation data to the multi-plant controller forremote analysis by the analysis module.
 6. The control system of claim1, wherein the interface unit is configured to provide a remoteinterface to authorized access devices to access the monitoring program,and wherein the remote interface is operable to allow authorized accessdevices to define or control operations of the operation unit includingat least one of collecting real-time operation data with the sensormodule and performing an adjustment of an operation of the antimicrobialapplication equipment with the adjustment module.
 7. The control systemof claim 6, wherein the remote interface is operable to allow authorizedaccess devices to one or more of adjust an operation of theantimicrobial application equipment, define administrative parametersused by the analysis module to analyze operation data, define setpoints, and define administrative decision rules.
 8. The control systemof claim 6, wherein the interface unit comprises multiple access levelsproviding different functionalities to authorized access devices foreach access level.
 9. The control system of claim 8, wherein the accesslevels are limited by location of the access device.